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<p>Additive manufacturing (AM) particularly 3D printing, is redefining rocket engine development in the cryogenic propulsion sector by enabling the rapid, precise, and cost-efficient fabrication of complex components. This review synthesizes recent advances, including the development of 3D-printed aerospike engines and rotating detonation rocket engines (RDREs), which collectively enhance fuel efficiency, reduce structural mass, and incorporate advanced cooling systems vital for extended space missions. A distinctive contribution of this study is its in-depth examination of engineering challenges and solutions, such as the optimization of microchannel geometries for non-Newtonian cryogenic fuel flow, the adoption of high-performance alloys like GRCOP-42, and the integration of embedded sensors for real-time health monitoring. The pivotal role of computational modelling and simulation in refining printed geometries, improving thermal regulation, and maximizing propulsion efficiency is critically assessed. Furthermore, this review presents a comprehensive classification of AM technologies applied across aerospace domains—including rockets, satellites, missiles, and high-performance aircraft highlighting their potential to reduce lead times, minimize material waste, and overcome traditional manufacturing constraints. Special emphasis is placed on multi-material printing, reinforcement strategies for ultra-lightweight structures, and innovations in cryogenic-specific AM. By consolidating recent breakthroughs and addressing persistent barriers, this work positions additive manufacturing as a transformative enabler for next-generation aerospace engineering, driving advancements in propulsion performance, cost-effectiveness, and sustainability.</p>

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3D printing in cryogenic aerospace propulsion: Materials, design optimization, and performance advances

  • 期刊论文

  • 发表日期：

    2026年4月9日

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  • Natrayan Lakshmaiya,
  • R. Endymion Grosious

摘要

Additive manufacturing (AM) particularly 3D printing, is redefining rocket engine development in the cryogenic propulsion sector by enabling the rapid, precise, and cost-efficient fabrication of complex components. This review synthesizes recent advances, including the development of 3D-printed aerospike engines and rotating detonation rocket engines (RDREs), which collectively enhance fuel efficiency, reduce structural mass, and incorporate advanced cooling systems vital for extended space missions. A distinctive contribution of this study is its in-depth examination of engineering challenges and solutions, such as the optimization of microchannel geometries for non-Newtonian cryogenic fuel flow, the adoption of high-performance alloys like GRCOP-42, and the integration of embedded sensors for real-time health monitoring. The pivotal role of computational modelling and simulation in refining printed geometries, improving thermal regulation, and maximizing propulsion efficiency is critically assessed. Furthermore, this review presents a comprehensive classification of AM technologies applied across aerospace domains—including rockets, satellites, missiles, and high-performance aircraft highlighting their potential to reduce lead times, minimize material waste, and overcome traditional manufacturing constraints. Special emphasis is placed on multi-material printing, reinforcement strategies for ultra-lightweight structures, and innovations in cryogenic-specific AM. By consolidating recent breakthroughs and addressing persistent barriers, this work positions additive manufacturing as a transformative enabler for next-generation aerospace engineering, driving advancements in propulsion performance, cost-effectiveness, and sustainability.