Innovative Space Carrier partnership to use WAAM3D Additive Manufacturing in propellant tank development
August 19, 2024
Innovative Space Carrier Inc (ISC), Tokyo, Japan, has partnered with WAAM3D, Milton Keynes, UK; Cranfield University, Wharley End, UK; and Aichi Sangyo Co Ltd, Tokyo, to accelerate the development of propellant tanks for space transportation systems. The collaboration will leverage Wire Arc Additive Manufacturing (WAAM) technology to develop components and structures.
“Although we are a venture company founded in May 2022, we have collaborated with over forty companies, organisations, and educational institutions in Japan,” stated Kojiro Hatada, ISC CEO. “In April this year, we partnered with Ursa Major Technologies, a US rocket engine development company, and established a local subsidiary. Now, we are collaborating with global experts in 3D printing. Our goal is ‘Wakon Yosai’ – to humbly learn from partners with advanced knowledge both domestically and internationally, reflect these strengths in Japan, rapidly enhance development speed, and establish space transportation technologies that can compete globally, contributing to the growth of Japan’s space industry.”
ISC aims to develop a reusable space transport vehicle within five years. To achieve this, it intends to improve development efficiency by using an agile development approach instead of the traditional waterfall model. In December last year, ISC conducted its first test and undertook what it called Japan’s first ‘tripropellant’ combustion test, confirming the effectiveness of its proprietary P4SD (Platform for Space Development) research and development platform.
Additive Manufacturing machines are crucial for achieving agile development. By shortening the manufacturing period, ISC will be able to quickly repeat the processes of manufacturing, testing, and optimising, thereby enhancing development speed. Additionally, AM machines offer significant advantages in management and assembly by enabling integrated manufacturing, eliminating the need for separate part production and assembly. The high degree of freedom in shaping allows for optimal designs, improving functionality while reducing weight.
Partners
WAAM3D, a spin-off from Cranfield University, produces technology utilised in various industries including space, oil & gas, and mining. WAAM3D’s equipment theoretically has no size limitations for the workpieces it can create, but generating shaping paths, fine-tuning shaping conditions, and controlling heat input remain significant challenges. WAAM3D has developed software and various sensors to assist with these issues, enabling visualisation and feedback control of the deposition process. As part of the collaboration with ISC, WAAM3D will sell Additive Manufacturing machines to ISC to manufacture the propellant tanks.
Dr Filomeno Martina, CEO of WAAM3D, stated, “We are incredibly excited to work on such an ambitious project. With partners of such caliber, we look forward to pushing the boundaries of size, integrity, and value creation. WAAM3D continues to be the first choice when performance matters.”
Cranfield University, with over fifteen years of research in metal AM, is reputed to house one of the world’s largest metal Additive Manufacturing facilities. The university’s Welding and Additive Manufacturing Center conducts research in material development, cold processing, advanced processes, and partial manufacturing. As part of this collaboration, the university’s expertise will be utilised in the manufacturing of propellant tanks.
“Cranfield University is very pleased to be involved in supporting AS and ICS on their journey into the use of WAAM technology for their space applications,” stated Stewart Williams, CTO of WAAM3D. “The Welding and Additive Manufacturing Centre at Cranfield has a rich history of innovating in WAAM for space, and we look forward to supporting WAAM3D, AS, and ISC with the solutions they need to reach their objectives.”
Established eighty years ago, Aichi Sangyo was an early adopter of metal Additive Manufacturing in Japan. The company provides a total AM solution by integrating the three key elements of metal AM: production machine, materials, and design. In this collaboration, Aichi Sangyo will utilise WAAM3D’s AM machines—purchased by ISC—to develop manufacturing technologies for propellant tanks.
