UK-based rocket manufacturer Skyrora is leading an innovative project in partnership with the European Space Agency (ESA) focused on advancing propulsion materials through 3D printing. Together with Metalysis and Thermo-Calc Solutions, Skyrora is set to develop and 3D print a new high-temperature alloy named Tanbium. This development aims to enhance the performance of rocket engines while decreasing production costs and reducing Europe’s dependence on imported materials.
Tanbium was conceived under the ESA’s General Support Technology Programme and is engineered to outperform conventional aerospace alloys, including C103 and IN718. By utilizing 3D printing technology, Tanbium promises significant advantages: up to 30% weight savings, improved temperature resistance, prolonged burn times, and a reduction in material waste by as much as 95%. Additionally, it is estimated that employing Tanbium will lower production costs by 40%.
Skyrora will implement the project using its Skyprint systems, which include one of Europe’s largest Directed Energy Deposition (DED) 3D printers. Derek Harris, Skyrora’s Director of Business Development, highlighted the project’s significance for European self-reliance, stating that Tanbium will facilitate full domestic sourcing, utilizing powders produced by Metalysis with components printed and tested by Skyrora.
The technical team behind the project believes Tanbium represents a significant advancement in propulsion materials. Ida Berglund, Managing Director at Thermo-Calc Solutions, noted that the alloy provides unprecedented performance and manufacturability improvements.
This ESA-supported initiative also aligns with sustainability efforts, promoting the production of low-carbon alloys and strengthening localized supply chains. The proprietary solid-state process used by Metalysis minimizes the high emissions typically associated with traditional metal manufacturing methods.
If successful, Tanbium could usher in a new era of efficient and lightweight rocket engines that are wholly manufactured in Europe, combining advanced 3D printing and innovative material science to enhance engine performance and transform the design and manufacturing of space hardware.