Mission Space
Design a rocket that could be built in place inside one of the four bays of the Vehicle Assembly Building (VAB) at Kennedy Space Center, which is 525 ft (160 m) tall. Utilize additive manufacturing (aka 3D printing) where possible, considering which materials might be able to be used and which ones may have to be brought in already manufactured.
A 450 ft tall 3-stage expendable rocket with 3D printable engines and outer shell.
Advantages of 3D printing a rocket include:
- Faster production process
- Fewer rocket parts
- Cost savings for NASA
- Rocket can be built on site in VAB
Each part of the outer shell, which uses aluminum/titanium alloy, can be 3D printed with a large metal platform and a movable 3D printer that goes above the platform in 3 dimensions to print the shell.
As for propellant, first stage uses liquid Kerosene fuel and the upper stages use liquid nitrogen tetroxide fuel. The 4 boosters use solid fuel and each has one engine.
The 3D printable parts include:
- The entire outer shell
- 13 engines
- Electronics in the payload and guidance system
- Chairs for passengers
- Bolts, screws
The fuel and hermetic apparatus need to be manufactured and brought to site.
The rocket can exit the 456 ft high door of VAB and be transported to the launch pad by truck.
