\u201cWhere is everybody?\u201d asked Enrico Fermi when contemplating the apparent contradiction of between the lack of evidence of extraterrestrial life and the high probability of life existing outside Earth. Since Fermi posed this question, multiple hypotheses (19 according to Wikipedia) have arisen to explain Fermi\u2019s Paradox (as the contradiction is now known). Space Exploration Technologies (Space X) is trying to save human-kind from one of these hypotheses (Periodic extinction by natural events) by making humans a multi planetary species. With the fear of stating the obvious, achieving Space X\u2019s goal is no easy thing. Elon Musk, Space X\u2019s CEO, estimates that to reach Mars \u201cwe need to improve cost per ton by 5 million percent. [1]\u201d To achieve the cost per ton objective Space X has been striving for full re-usability of its rockets, and within this effort, Additive Manufacturing has played a key role.<\/p>\n
Additive Manufacturing (3D printing) has not lived up to its hype (yet), has clear benefits for the aerospace industry [2]. 3D-printed parts provide Space X with the opportunity to build spacecrafts that are more reliable, robust and efficient [3] – criteria that work in conjunction to achieve reusability of the rocket. In 2014, Space X tried for the first time an engine component (Main Oxidizer Valve) in a rocket launch. Space X stated that vis a vis with a traditional cast part, \u201ca printed valve body has superior strength, ductility, and fracture resistance, with a lower variability in materials properties. [4]\u201d<\/p>\n
The development of the SuperDraco engine is a further example of Space X commitment to 3D-printing. This new engine will be wholly 3D-printed [5] setting an important milestone for the aerospace industry [6]. The importance of 3D printing to achieve the development of the SuperDraco engine is described by Elon Musk: \u201cit is a very complex engine, and it was very difficult to form all the cooling channels, the injector head, and the throttling mechanism. Being able to print very high strength advanced alloys, I think, was crucial to being able to create the SuperDraco engine as it is. [7]\u201d<\/p>\n
The increased strength and\/or increased lightness is just a part of the benefits of 3D-printing. The speed of developing parts is also a big bonus. Reviewing the previous examples sheds light on this benefit. The production of the Main Oxidizer Valve (MOV) went down to a couple of hours when using 3D-printing compared to multiple months through typical casting cycles [8]. For the SuperDraco engine, 3D-printing reduced the lead time from Initial Concept to the first Hotfire Test in one order of magnitude (30 months to 3 months) [9]. These gains are achieved by faster manufacturing but also because of the feasibility to skip prototyping with other materials (e.g., plastic). Metal 3D-printed parts are both functional as prototypes and as end-use production parts [10].<\/p>\n
Given the strategic importance of 3D-printing for Space X, it has developed all capabilities in-house [11]. Additionally, Space X is also pushing the limit on manufacturing by increasing the ease of design and linking it to 3D-printing. The company is integrating sensor and visualization technologies to view and modify designs more efficiently than by using 2D tools. Combined with the strides made in 3D printing, Space X expects to build a faster route between idea and reality [12]. Elon Musk considers that these advancements will \u201crevolutionize design to manufacturing. [13]\u201d<\/p>\n
From a personal view I would consider three key areas on where management should focus in the future. First, it should further increase its capabilities of linking design and manufacturing (as mentioned in the previous paragraph). Second, it should analyze the development of new 3D-printing capabilities. The new engine for the company\u2019s BFR rocket will only be 40% 3D-printed (measured by mass) [14]. This change from the 100% 3D-printed SuperDraco exposes some of the limits for 3D-printing like size. Overcoming 3D-printing constraints will enable Space X to reap its benefits in additional parts of its rockets.<\/p>\n
Open questions:<\/p>\n
How does the existing infrastructure for traditional manufacturing (if at all) affects 3D printing ability to compete in certain applications? Would a more extensive use of 3D-printing provide a boost in efficiency or is a technological improvement needed to move away from grinding and milling?<\/p>\n
(772 words)<\/p>\n
Footnotes:<\/p>\n
[1] \u201cFrom Energy To Transport To Healthcare, Here Are 8 Industries Being Disrupted By Elon Musk And His Companies\u201d, CB Insights, 2018, https:\/\/app-cbinsights-com.prd2.ezproxy-prod.hbs.edu\/research\/report\/elon-musk-companies-disruption\/<\/a>, accessed November 2018.<\/p>\n [2] Filemon Schoffer, \u201cMetal 3D printing takes flight\u201d, TechCrunch, 2016, https:\/\/techcrunch.com\/2016\/07\/24\/metal-3d-printing-takes-flight\/<\/a>, accessed November 2018.<\/p>\n [3] \u201cSPACEX LAUNCHES 3D-PRINTED PART TO SPACE, CREATES PRINTED ENGINE CHAMBER\u201d, Space X, July 2014, https:\/\/www.spacex.com\/news\/2014\/07\/31\/spacex-launches-3d-printed-part-space-creates-printed-engine-chamber-crewed<\/a>, accessed November 2018.<\/p>\n [4] Ibid<\/p>\n [5] Ibid<\/p>\n [6] \u201cUnveil event\u201d, Space X, May 2014, https:\/\/www.youtube.com\/watch?v=yEQrmDoIRO8<\/a>, accessed November 2018.<\/p>\n [7] Jeff Foust, \u201cSpaceX unveils its \u201c21st century spaceship\u201d\u201d, May 2014, http:\/\/www.newspacejournal.com\/2014\/05\/30\/spacex-unveils-its-21st-century-spaceship\/<\/a>, ccessed November 2018.<\/p>\n [8] \u201cSPACEX LAUNCHES 3D-PRINTED PART TO SPACE, CREATES PRINTED ENGINE CHAMBER\u201d, Space X, July 2014, https:\/\/www.spacex.com\/news\/2014\/07\/31\/spacex-launches-3d-printed-part-space-creates-printed-engine-chamber-crewed<\/a>, accessed November 2018.<\/p>\n [9] Ibid<\/p>\n [10] \u201cDirect Metal Laser Sintering\u201d, Protolabs, 2018, https:\/\/www.protolabs.com\/services\/3d-printing\/direct-metal-laser-sintering\/<\/a>, accessed November 2018.<\/p>\n [11] \u201cSPACEX LAUNCHES 3D-PRINTED PART TO SPACE, CREATES PRINTED ENGINE CHAMBER\u201d, Space X, July 2014, https:\/\/www.spacex.com\/news\/2014\/07\/31\/spacex-launches-3d-printed-part-space-creates-printed-engine-chamber-crewed<\/a>, accessed November 2018.<\/p>\n [12] \u201cThe Future of Design\u201d, Space X, September 2013, https:\/\/www.youtube.com\/watch?v=xNqs_S-zEBY<\/a>, accessed November 2018.<\/p>\n [13] Ibid<\/p>\n