Wipro 3D and ISRO’s additively manufactured rocket engine opens up sustainable space exploration
June 3, 2024
Wipro 3D, the Additive Manufacturing business of Wipro Infrastructure Engineering (WIN), based in Bengaluru, India, in collaboration with the Indian Space Research Organisation (ISRO), has reported the successful Additive Manufacturing of the PS4 rocket engine used to power the 4th stage of the Polar Satellite Launch Vehicle (PSLV).
“Wipro 3D’s expertise in Additive Manufacturing has been instrumental in realising our vision for sustainable space exploration,” stated Dr V Narayanan, Director, Liquid Propulsion Systems Centre (LPSC), ISRO. “The successful integration of the 3D printed PS4 engine into our mission marks a significant milestone for ISRO and sets new standards of advanced manufacturing in the space industry.”
The PSLV is an expendable launch system designed to place earth observation and scientific research satellites into precise orbits, enabling multiple applications like remote sensing, oceanography, cartography, mineral mapping, disaster warning, etc. In an effort to ensure accurate orbital placement, the PS4 stage is equipped with advanced navigation, guidance, and control systems. Its ability to support multiple restart capability and payload adapters enhances its adaptability for different kinds of spacecraft missions.
The PS4 engine, traditionally manufactured through conventional machining and welding, underwent a redesign for Additive Manufacturing production. Through the adoption of Laser Beam Powder Bed Fusion (PBF-LB) AM technology, Wipro 3D and ISRO consolidated the multiple and diversified intricate components of the PS4 engine into a single unified production unit, enhancing production efficiency and structural integrity.
The design features complex integral cooling channels, prioritises sustainability and efficiency, and has minimal material wastage and post-build machining operations. Rigorous testing of the hardware at the facilities ISRO Propulsion Complex in Mahendragiri confirmed the engine’s performance under real-world conditions, meeting the design safety and efficiency standards.
Yathiraj Kasal, GM & Business Head, Wipro 3D, stated, “We’re honoured to collaborate with ISRO on this pioneering project, highlighting the potential of advanced manufacturing in Space. This partnership not only advances ISRO’s ‘Make in India’ initiative but also promotes domestic innovation and manufacturing. It is an honour and a privilege to manufacture the PS4 engine for the PSLV vehicle. We are eagerly awaiting the successful second round of testing to fly high alongside ISRO.
“With ISRO’s backing, this project embodies their commitment to sustainable and cost-effective space missions, facilitating rapid design iterations and enhancing launch efficiency. We extend our sincere gratitude to Dr V Narayanan and the exceptional ISRO team for their trust in us. As we enter into the project’s next phase, we are totally dedicated to providing unwavering support to ensure its success,” Kasal continued.
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