On November 6, computational engineering leader LEAP 71 announced a collaboration with Nikon SLM Solutions, successfully completing manufacturing validation for a large-scale metal 3D-printed rocket engine component.
The two companies have produced a 2000 kN full-flow staged combustion (FFSC) rocket engine injector head, a critical component of LEAP 71’s XRB-2E6 methane/LOX rocket engine.
Another Landmark Case of Integrated Metal 3D Printing
Traditionally, a rocket injector is not a single component—it’s a complex assembly made up of hundreds or even thousands of precision parts, joined together through intricate manufacturing processes.
What LEAP 71 and Nikon SLM have demonstrated is the transformation of this entire system into a single, monolithic component grown directly through metal 3D printing — a typical breakthrough case showcasing the revolutionary potential of integrated additive manufacturing.
The injector head measures 600 mm in diameter and is printed from aerospace-grade nickel alloy IN718, making it one of the largest and most complex 3D-printed spacecraft components ever produced. It was fabricated using the high-speed NXG 600E industrial additive manufacturing system, marking a major milestone in the partners’ collaboration that has been underway for over two years.
Designed to Power Heavy-Lift Rockets
The Full-Flow Staged Combustion (FFSC) cycle is regarded as a key milestone in rocket propulsion technology. It is one of the most efficient ways to convert the chemical energy of propellants into thrust. However, this advanced engine cycle also presents major engineering challenges — such as managing the high-temperature pre-burned methane and oxygen that flow through the engine’s intricate injector system.
The XRB-2E6 engine delivers approximately 200 tons of thrust, comparable to the engines powering the world’s newest generation of heavy-lift launch vehicles. The company plans to conduct live tests in Q4 2027.
To achieve this, LEAP 71 is actively seeking partners to validate the manufacturing processes required for reliable engine production — leveraging large-scale metal 3D printing systems to make this ambitious goal a reality.
Integrating 3D Printing Process Parameters into a Large-Scale Engineering Model
The injector head was entirely generated by LEAP 71’s Noyron computational engineering model, specifically designed to withstand the extreme thermal loads and pressures of a Full-Flow Staged Combustion (FFSC) rocket engine cycle.
According to Nikon SLM’s Head of Additive Material Products and Development,
“When LEAP 71 approached us to produce a key component for one of the most advanced space propulsion systems in the world, we knew this was a challenge we couldn’t resist. We worked closely with LEAP 71 to integrate critical manufacturing parameters directly into their Noyron system, optimizing the interactions between each step of the process chain.
As a result, we were not only able to reliably print this complex structure on the NXG 600E, but also used our IN718 PROD parameter set to complete the build in less than four days — a record-breaking achievement that is essential for cost-effective production and rapid iteration during validation.”
Integrated Design and Rapid Iteration
Metal additive manufacturing lies at the heart of LEAP 71’s philosophy, as it empowers the Noyron system to design highly complex and efficient structures while minimizing manufacturing constraints. By printing the component as a single integrated part, LEAP 71 eliminates the need to assemble hundreds of standardized elements that would otherwise require precise machining and sealing. This approach significantly enhances system reliability and reduces production time from weeks to just a few days.
Noyron can generate an entire engine design within hours based on abstract specifications, without any human intervention. The final result is a functionally integrated component that requires no assembly and minimal post-processing before being delivered directly to the test stand.
This embodies LEAP 71’s philosophy of rapid and frequent real-world testing, using physical results to continuously refine and enrich Noyron’s design capabilities.
