https://leap71.com/2024/06/18/leap-71-hot-fires-3d-printed-liquid-fuel-rocket-engine-designed-through-noyron-computational-model/ [L71-Logo-A-Tight] * Home * News * Gallery + Images + Models * PicoGK * Noyron + Overview + Noyron RP * About + About LEAP 71 + Technology + Computational Engineering + Press and Media * Contact Us [TK5_PRESS] LEAP 71 hot-fires 3D-printed liquid-fuel rocket engine designed through Noyron Computational Model Jun 18, 2024 Dubai, June 18th, 2024 -- for immediate release LEAP 71, a Dubai-based AI engineering company, announced today the successful test firing of a liquid rocket engine created entirely through Noyron, the company's Large Computational Engineering Model. The engine was designed autonomously without human intervention and then 3D-printed in copper. The rocket thruster was successfully hot-fired at a rocket test stand in the UK. The engine with 5 kN (500 kg / 1124 lbf) of thrust, generated the expected 20,000 horsepower, and completed all tests, including a long duration burn. Josefine Lissner, Aerospace engineer, and Managing Director of LEAP 71 said: "This is an important milestone for us, but also for the entire industry. We can now automatically create functional rocket thrusters and directly move to practical validation. From final specification to manufacturing, the design of this engine took less than 2 weeks. In traditional engineering, this would be a task of many months, or even years. Each new engine iteration takes only minutes. Innovation in space propulsion is hard, and costly. With our approach, we hope to make space more accessible for everyone." [4EB078AB-8CC4-4B5D-8778-38391705C06F] The generated engine uses cryogenic Liquid Oxygen (LOX) and Kerosene as propellants. The copper combustion chamber is regeneratively cooled and the injector head features state-of-art coaxial swirler to mix the propellants. Lin Kayser, co-founder of LEAP 71 said: "Our company is at the forefront of the new field of Computational Engineering, where sophisticated machines can be designed without manual work. The paradigm significantly accelerates the pace of innovation for real-world objects. The fact that the Noyron thruster operated nominally on the first try, confirms that the approach is working. The method can be applied to any field of engineering." So proud of @LissnerJosefine - steely-eyed rocket woman. We just test fired a 5kN kerolox thruster, designed completely in-house at @leap_71 - it performed flawlessly and reached steady state. Kerosene regeneratively cooled and cryogenic liquid oxygen as oxidizer. Koaxial swirl... pic.twitter.com/dZFCIjvk7v -- Lin Kayser (@linkayser) June 15, 2024 LEAP 71 worked with leading German metal 3D printing company AMCM on the production of the thruster. It was then post-processed at the University of Sheffield and prepared for the test. The hot fire was performed at Airborne Engineering, Ltd. in Wescott, UK. LEAP 71 will use the data from the test to further advance Noyron. The company is working with leading aerospace companies in the US, Europe and Asia on the commercialization of the the resulting rocket engines. [E087E0EC-BABB-486D-8927-FC9865B77207] About LEAP 71 LEAP 71 is a company based in Dubai, UAE, founded by aerospace engineer Josefine Lissner and serial entrepreneur Lin Kayser. LEAP 71's mission is to radically advance the progress in engineering through the new field of Computational Engineering. The company uses sophisticated software algorithms to build physical products. LEAP 71 has developed the Large Computational Engineering Model Noyron, which is considered the most advanced model available. LEAP 71 works with customers all over the world, including the US, Korea, Europe, and China to design products in fields ranging from aerospace and electric mobility, to heat exchangers. LEAP 71 has open-sourced a significant part of the technology stack, including PicoGK ("peacock"), a compact and robust geometry kernel, that enables the creation of very complex physical objects. Most of LEAP 71's parts are 3D printed on advanced industrial Additive Manufacturing machines. LEAP 71 June 2024 hot fire backgrounder Achievements * First rocket engine built entirely through a computational model without human intervention * Likely the shortest time from spec to manufacturing for a new rocket engine (2 weeks, usually this process takes many months in manual engineering using CAD) * First liquid fueled rocket engine developed in the United Arab Emirates * Engine worked on the first attempt * No CAD was used in the design [35709E8B-BF87-485F-9402-C738B19FF029] Rocket thruster project The development of the Noyron TKL-5 rocket thruster, which was successfully hot fired in June 2024, is an internal LEAP 71 project to showcase the capabilities of the Noyron Large Computational Engineering Model. The design phase of the thruster took less than 2 weeks from final specification to send-off to manufacturing. The generation of new design variations takes less than 15 minutes on a regular computer. The thruster geometry was printed at AMCM, a leading metal 3D printing company in Germany. LEAP 71 partnered with the University of Sheffield, UK, and Airborne Engineering, a UK test site provider, for the hot fire campaign. The University of Sheffield's UK Race to Space team provided a wealth of practical feedback, and completed all the post-machining steps and instrumentation required to move the thruster to the test stand. Technical advisor Sam Rogers, Chief Design Officer at Gravity Industries, provided important guidance throughout the project. The rocket engine LEAP 71 chose a thrust level of 5kN (equivalent to 500 kg / 1120 lbs lift mass or 20,000 horsepower). This is a relatively compact engine, which would be suitable for a final kick stage of an orbital rocket. The thruster runs on cryogenic Liquid Oxygen (LOX) and Kerosene, a combination that is used by many advanced rocket systems, including the SpaceX Falcon 9 and the venerable Saturn V moon rocket. LEAP 71 intentionally made that selection despite the propellants being more challenging to operate than others commonly used for small engines. The engine was printed from copper (CuCrZr) using an EOS M290 metal printer. Copper has a low melting point, but enables compact high-performance engines, when actively cooled. If cooling failed, it would melt immediately. [E4EDBC79-C943-4A24-BA42-7ABD41CC093C] The engine uses thin cooling channels that swirl around the chamber jacket, with a variable cross sections as thin as 0.8mm. The Kerosene is pressed through the channels to cool the engine and prevent it from melting. Both propellants are then injected into the combustion chamber. The combustion temperature inside the engine is around 3000oC, whereas the engine surface stays below 250oC, because of the active cooling. The propellants are injected into the engine using a coaxial swirl injector head. This injector type is considered the most advanced. Additional film cooling is provided by directing a portion of the fuel through tiny holes near the wall of the combustion chamber. [2D80538D-6CF2-4B06-B25B-CF0E19108D98] A multitude of measurement ports for temperature and pressure data enable information to flow back into the Noyron computational model. The test The hot fire was conducted in Wescott, UK, at the test site of Airborne Engineering on Friday, June 14, 2024. The engine was hot fired for an initial 3.5 seconds using an oxidizer to fuel ratio of 1.8, which is lower than the nominal 2.3. By using less oxidizer, the engine burns slightly less hot. After confirming that the engine performed well and all temperatures were in the expected range, the engine was tested for a full 12 second long-duration burn at a nominal oxidizer-to-fuel ratio of 2.3. The engine performed as expected. It achieved steady-state, which means it can essentially be operated as long as needed. The burn time was only limited by the fuel supply at the test site. [D7EEEF8C-5776-429C-BB5B-673424D2D4B6] Post analysis The engine was disassembled at the University of Sheffield the next day, and careful inspection confirmed that it remained fully intact. The thruster will stay in the UK for future tests. Initial analysis of the data show that the pressure drop (the resistance) of the cooling channels was higher than modeled, which is due to the actual surface roughness of the 3D print. The team will post-smooth the existing engine while Noyron's cooling channel logic has already been updated to improve predictions and the design for future engines. [03ADB8BB-9168-4ABF-9F13-845536361D5B] Latest News Solideon and LEAP 71 collaborate on large-scale 3D-printed space hardware Solideon and LEAP 71 collaborate on large-scale 3D-printed space hardware 18 Mar 2024 LEAP 71, MIMO TECHNIK, and ASTRO Test Lab team up to build fully-qualified aerospace products based on Computational Engineering LEAP 71, MIMO TECHNIK, and ASTRO Test Lab team up to build fully-qualified aerospace products based on Computational Engineering 11 Mar 2024 LEAP 71 is open sourcing its foundational Computational Engineering technology at GITEX Global in Dubai LEAP 71 is open sourcing its foundational Computational Engineering technology at GITEX Global in Dubai 18 Oct 2023 * Follow Rocket engines are powerful - this small thruster can lift the weight of a horse into the air by the sheer power of its exhaust - producing the power of 20,000 horses in the process. Rocket engines are powerful - this small thruster can lift the weight of a horse into the air by the sheer power of its exhaust - producing the power of 20,000 horses in the process. #cnn today #cnn today Proud parents before the test fire. @josefinelissner is holding up the connector end of the coaxial swirl injector head. @lin_kayser is holding the @noyron.ai TKL-5 copper combustion chamber. Together they form the entire thruster. Proud parents before the test fire. @josefinelissner is holding up the connector end of the coaxial swirl injector head. @lin_kayser is holding the @noyron.ai TKL-5 copper combustion chamber. Together they form the entire thruster. Big thank you to @eos3dprinting sister company #AMCM for the excellent #3dprint in #copper (CuCrZr). The thruster withstood everything we threw at it. Big thank you to @eos3dprinting sister company #AMCM for the excellent #3dprint in #copper (CuCrZr). The thruster withstood everything we threw at it. Before the storm. @noyron.ai TKL-5 thruster. Before the storm. @noyron.ai TKL-5 thruster. Looking at the coaxial swirlers which mix the liquid oxygen and kerosene before combustion. Looking at the coaxial swirlers which mix the liquid oxygen and kerosene before combustion. #coaxialswirl injector head of our @noyron.ai thruster before assembly. #coaxialswirl injector head of our @noyron.ai thruster before assembly. #startmeup #startmeup Turn up the volume for the sound of 20,000 horsepowers. The first liquid rocket engine made in @dubai - test fired this weekend in the UK. Created through @noyron.ai , our Large Computational Engineering Model. The first #AI designed rocket engine. 5kN, cryogenic Liquid Oxygen and Kerosene as propellants. #3dprinted from #copper. # ComputationalEngineering Turn up the volume for the sound of 20,000 horsepowers. The first liquid rocket engine made in @dubai - test fired this weekend in the UK. Created through @noyron.ai , our Large Computational Engineering Model. The first #AI designed rocket engine. 5kN, cryogenic Liquid Oxygen and Kerosene as propellants. #3dprinted from #copper. # ComputationalEngineering Frozen engine before our hot fire. Frozen engine before our hot fire. Nothing more satisfying than seeing things coming together. Nothing more satisfying than seeing things coming together. #ComputationalEngineering allows us to build better electric motors with complex coil shapes and internal cooling channels which support higher currents. #ComputationalEngineering allows us to build better electric motors with complex coil shapes and internal cooling channels which support higher currents. Taking some inspiration from Gerald O'Neill's classic book. Taking some inspiration from Gerald O'Neill's classic book. This transparent view of a helix heat exchanger created through # ComputationalEngineering shows the intricate internal structures. The @picogk source code for the generation of this model is available on our GitHub. This transparent view of a helix heat exchanger created through # ComputationalEngineering shows the intricate internal structures. The @picogk source code for the generation of this model is available on our GitHub. Multimaterial #3dprinting allows us to build #electricmotors with complex coil geometries, shaping the magnetic field for higher efficiency. This one was printed using the @fraunhofer.igcv dual metal process on a @nikonslmsolutions machine Multimaterial #3dprinting allows us to build #electricmotors with complex coil geometries, shaping the magnetic field for higher efficiency. This one was printed using the @fraunhofer.igcv dual metal process on a @nikonslmsolutions machine We just added a downloadable models section to our website. Download an STL and #3dprint it. leap71.com/downloads - more models coming soon! We just added a downloadable models section to our website. Download an STL and #3dprint it. leap71.com/downloads - more models coming soon! 1 kN vacuum thruster designed with Noyron RP, our # ComputationalEngineering Model for space propulsion systems. Built on @picogk, our #opensource geometry kernel. 1 kN vacuum thruster designed with Noyron RP, our # ComputationalEngineering Model for space propulsion systems. Built on @picogk, our #opensource geometry kernel. Detail of an injector head designed using Noyron RP on @picogk Detail of an injector head designed using Noyron RP on @picogk @aconity3d printed one of our heat exchangers in #copper. Here it is in all its glory. #ComputationalEngineering @aconity3d printed one of our heat exchangers in #copper. Here it is in all its glory. #ComputationalEngineering Test #3dprint of a #multimaterial stator for an #axialflux # electricmotor. Designed through our #ComputationalEngineering Model @noyron.ai and built on @picogk our #opensource geometry kernel. Test #3dprint of a #multimaterial stator for an #axialflux # electricmotor. Designed through our #ComputationalEngineering Model @noyron.ai and built on @picogk our #opensource geometry kernel. Regeneratively cooled nozzle extension for a vacuum-optimized #rocket #thruster designed with Noyron RP, our #ComputationalEngineering Model for space propulsion. Regeneratively cooled nozzle extension for a vacuum-optimized #rocket #thruster designed with Noyron RP, our #ComputationalEngineering Model for space propulsion. Introducing Noyron - our Large Computational Engineering Model, which distills all the knowledge we have codified into rules and algorithms over the past year. Noyron allows us to build complex products, rooted in engineering logic, physics, and manufacturing experience. Noyron lies at the root of all our bespoke customer projects and forms the basis of more specialized #ComputationalEngineering Models for fields like space propulsion and electric mobility. Introducing Noyron - our Large Computational Engineering Model, which distills all the knowledge we have codified into rules and algorithms over the past year. Noyron allows us to build complex products, rooted in engineering logic, physics, and manufacturing experience. Noyron lies at the root of all our bespoke customer projects and forms the basis of more specialized #ComputationalEngineering Models for fields like space propulsion and electric mobility. #ctscan of one of our #3dprinted #rocket injector heads, designed through #ComputationalEngineering. Printed by @aconity3d and analyzed by @visiconsult #ctscan of one of our #3dprinted #rocket injector heads, designed through #ComputationalEngineering. Printed by @aconity3d and analyzed by @visiconsult Family picture of a 1kN and 5kN rocket thruster generated through our #ComputationalEngineering Model for space propulsion. Family picture of a 1kN and 5kN rocket thruster generated through our #ComputationalEngineering Model for space propulsion. * Follow Rocket engines are powerful - this small thruster can lift the weight of a horse into the air by the sheer power of its exhaust - producing the power of 20,000 horses in the process. Rocket engines are powerful - this small thruster can lift the weight of a horse into the air by the sheer power of its exhaust - producing the power of 20,000 horses in the process. #cnn today #cnn today Proud parents before the test fire. @josefinelissner is holding up the connector end of the coaxial swirl injector head. @lin_kayser is holding the @noyron.ai TKL-5 copper combustion chamber. Together they form the entire thruster. Proud parents before the test fire. @josefinelissner is holding up the connector end of the coaxial swirl injector head. @lin_kayser is holding the @noyron.ai TKL-5 copper combustion chamber. Together they form the entire thruster. Big thank you to @eos3dprinting sister company #AMCM for the excellent #3dprint in #copper (CuCrZr). The thruster withstood everything we threw at it. Big thank you to @eos3dprinting sister company #AMCM for the excellent #3dprint in #copper (CuCrZr). The thruster withstood everything we threw at it. Before the storm. @noyron.ai TKL-5 thruster. Before the storm. @noyron.ai TKL-5 thruster. Looking at the coaxial swirlers which mix the liquid oxygen and kerosene before combustion. Looking at the coaxial swirlers which mix the liquid oxygen and kerosene before combustion. #coaxialswirl injector head of our @noyron.ai thruster before assembly. #coaxialswirl injector head of our @noyron.ai thruster before assembly. #startmeup #startmeup Turn up the volume for the sound of 20,000 horsepowers. The first liquid rocket engine made in @dubai - test fired this weekend in the UK. Created through @noyron.ai , our Large Computational Engineering Model. The first #AI designed rocket engine. 5kN, cryogenic Liquid Oxygen and Kerosene as propellants. #3dprinted from #copper. # ComputationalEngineering Turn up the volume for the sound of 20,000 horsepowers. The first liquid rocket engine made in @dubai - test fired this weekend in the UK. Created through @noyron.ai , our Large Computational Engineering Model. The first #AI designed rocket engine. 5kN, cryogenic Liquid Oxygen and Kerosene as propellants. #3dprinted from #copper. # ComputationalEngineering Frozen engine before our hot fire. Frozen engine before our hot fire. Nothing more satisfying than seeing things coming together. Nothing more satisfying than seeing things coming together. #ComputationalEngineering allows us to build better electric motors with complex coil shapes and internal cooling channels which support higher currents. #ComputationalEngineering allows us to build better electric motors with complex coil shapes and internal cooling channels which support higher currents. Taking some inspiration from Gerald O'Neill's classic book. Taking some inspiration from Gerald O'Neill's classic book. This transparent view of a helix heat exchanger created through # ComputationalEngineering shows the intricate internal structures. The @picogk source code for the generation of this model is available on our GitHub. This transparent view of a helix heat exchanger created through # ComputationalEngineering shows the intricate internal structures. The @picogk source code for the generation of this model is available on our GitHub. Multimaterial #3dprinting allows us to build #electricmotors with complex coil geometries, shaping the magnetic field for higher efficiency. This one was printed using the @fraunhofer.igcv dual metal process on a @nikonslmsolutions machine Multimaterial #3dprinting allows us to build #electricmotors with complex coil geometries, shaping the magnetic field for higher efficiency. This one was printed using the @fraunhofer.igcv dual metal process on a @nikonslmsolutions machine We just added a downloadable models section to our website. Download an STL and #3dprint it. leap71.com/downloads - more models coming soon! We just added a downloadable models section to our website. Download an STL and #3dprint it. leap71.com/downloads - more models coming soon! Contact us * Follow * Follow * Follow Explore (c) 2023 by LEAP 71 -- All Rights Reserved