NASA’s aluminum nozzle tests opened another route to lighter engines

What happened

NASA’s September 2024 report revisited successful testing of an aluminum printed rocket nozzle in fall 2023. The work involved Elementum 3D and its approach to making alloys more suitable for additive manufacturing.

Aluminum presents challenges including cracking during printing and limited temperature capability. The project combined modified material with large-scale deposition development to address a specific application.

The reported milestone is a ground test, not evidence that every aluminum alloy or printed engine is ready for flight. NASA also described commercial uses emerging from the collaboration.