Intuitive Machines
Sciaky manufactured a critical part for Intuitive Machines' IM-1 mission to the moon in February of this year.
The part, printed with an expensive, difficult to deposit refractory alloy on one of Sciaky's Electron Beam Additive Manufacturing (EBAM) systems, took only 16 hours to complete. The part itself is the upper section of the main engine nozzle, which provides the main source of thrust for descent. Sciaky produced two additional upper nozzle sections, which were provided to Intuitive Machines for testing.
By using wire feedstock instead of powder, EBAM minimizes waste and cost, leading to significant cost savings and sustainability advantages. Moreover, the ability to fabricate near-net shape parts reduces the need for costly post-processing and machining, optimizing production time and costs.
Intuitive Machines rigorously tested the part under hot fire testing conditions – burning fuel up to full throttle. After it was determined the part was suitable for end-use, it was assembled into the Nova-C lunar lander, Odysseus, for the IM-1 mission. As a part of the main engine of the lunar lander, the Sciaky-made upper nozzle section performed as required in the inhospitable environment of space.
The IM-1 Mission successfully landed the spacecraft on the moon's south pole region, marking the United States' first return since Apollo 17 in 1972 and the first commercial lunar lander to transmit valuable science data of each NASA payload from the lunar surface. The IM-1 Mission was part of NASA's Commercial Lunar Payload Services (CLPS) initiative, which is exploring and preparing the moon for crewed missions in the future.
The mission had a few challenges, but Intuitive Machines' concept was proven and the main objectives of the mission were met, as the lander sent back critical data and made the case for future missions of its kind. Sciaky is actively researching ways to improve upon its contributions to the aerospace sector.
Intuitive Machines is a diversified space exploration, infrastructure, and services company focused on fundamentally disrupting lunar access economics. The company's products and services are offered through its four in-space business units: Lunar Access Services, Orbital Services, Lunar Data Services, and Space Products and Infrastructure.
Sciaky's EBAM technology has enabled manufacturers to realize complex geometries and lightweight designs that were previously unattainable using traditional manufacturing methods. With the freedom to create intricate internal structures and consolidated assemblies, engineers can now optimize part performance and reduce weight, resulting in improved fuel efficiency and enhanced overall functionality.
Sciaky Inc., a subsidiary of Phillips Service Industries, markets its exclusive EBAM process as the fastest, most cost-effective 3D printing process for large-scale metal parts, allowing manufacturers to save significant time and money versus traditional manufacturing and rapid prototyping processes.