Selective Laser Melting of Lattice Structures for Propulsion System Thermal Control

Quadrus Advanced Manufacturing, LLC (QAM) is pleased to present this proposal for demonstrating an innovative approach for designing and manufacturing a rocket motor refractory metal component that simultaneously exhibits low production cost, light weight and low effective thermal conductivity. This pintle, which can be tailored for use in any controllable propulsion system, will feature an internal lattice structure—achievable only with modern additive manufacturing (AM), which puts metal ONLY where it is needed—that allows designers to maintain positive structural margins and reduce the thermal conduction path that otherwise places significant heat loads onto actuators, controllers and other electronic components in a modern solid propellant-based divert and attitude control systems (DACS). Phase I activities include identification of the optimum lattice architecture, but we otherwise anticipate it will incorporate distinct “sections” of varying lattice densities and unit cell arrangement. In the end, such a pintle design with integral lattice structures can withstand the thermal-mechanical loads while minimizing the thermal load it otherwise would conduct into the actuators, control electronics and sensors. Approved for Public Release | 21-MDA-11013 (19 Nov 21)