SMC makes first Australian bimetal, 3D-printed rocket thruster

CSIRO has announced the successful production of Australia’s first bimetal rocket thruster using multi-material additive manufacturing (3D printing). The thruster was developed by Space Machines Company (SMC) and manufactured at CSIRO’s Lab22 facility using a Nikon SLM Solution SLM280 2MA 3D metal printer.

Funded through the iLAuNCH Trailblazer program, the cutting-edge thruster will power Space Machine’s Optimus Viper, an Australian-made spacecraft designed for in-orbit inspection, servicing and logistics.

The innovation leverages multi-material laser powder bed fusion (LPBF) to combine two high-performance metals in a single print: high-strength steel for structural strength as the outer jacket and copper alloy for high thermal conductivity. This combination allows the thruster to endure extreme heat while remaining lightweight and robust, an uncommon design not typically seen in conventional, single-metal rocket propulsion systems.

“We strive to build sovereign space capabilities by developing, manufacturing and operating space technology right here in Australia,” said Darin Lovett, Executive Director of iLAuNCH. “We’re proud to support a project that demonstrates how Australian-led innovation is building world-class space technology and capability locally.”

Traditional methods for manufacturing rocket thrust chambers involve machining cooling channels into a copper liner and brazing it to a steel jacket — a costly, time-intensive process with multiple failure points. With multi-material 3D printing, both metals are printed simultaneously, reducing production complexity, cost and time while increasing design flexibility and durability.

“Space Machines Company is rapidly scaling production of our Optimus Viper vehicles to deliver persistent proximity operations and space domain awareness at unprecedented speed and scale,” said Rajat Kulshrestha, CEO of Space Machines Company. “By modifying our Scintilla thruster design to incorporate dual materials, we’ve gained the ability to rapidly experiment and optimise different material combinations — critical for achieving the propulsion performance our mass-produced spacecraft.”

The thruster forms a key part of Space Machine’s Scintilla propulsion system, which requires precise, repeatable and durable thrust to carry out close-proximity operations in orbit. The regenerative cooling provided by the copper alloy channels ensures the thruster can withstand repeated firings and long burn durations, while the steel jacket maintains structural integrity under pressure.

“This achievement showcases the potential of multi-material additive manufacturing for complex, high-performance parts,” said CSIRO Senior Research Scientist Dr Cherry Chen. “By placing each material exactly where it’s needed, we can improve functionality, reduce waste and open up new design possibilities for a wide range of industries.”

Image ©Damien Ford