Scottish space firm unveils world’s largest 3D printed rocket engine

The company, which is involved in plans to develop the UK’s first spaceport in Sutherland, Scotland unveiled the rocket at the opening of its new headquarters and rocket design facility in Forres in the Scottish Highlands.

Designed to deliver small satellites into Earth’s orbit, Orbex Prime is a two-stage rocket that’s claimed to be up to 30% lighter and 20% more efficient than any other vehicle in the small launcher category. It is also the first commercial rocket engine designed to work with bio-propane, a clean-burning, renewable fuel source that cuts carbon emissions by 90% compared to fossil hydrocarbon fuels.

The completed engineering prototype of the Stage 2 rocket (the stage that will transit into orbital flight after launch) is made from a specially-formulated lightweight carbon fibre and aluminium composite and includes the world’s largest 3D printed rocket engine. This was manufactured in a single piece without joins in partnership with additive manufacturer SLM Solutions. The company claims that given the extreme temperature and pressure fluctuations involved in space flight, this gives the engine an advantage over other rocket engines, which can suffer from weaknesses associated with joining and welding.