China successfully launched a reusable experimental spacecraft, with 3D printing technology serving as a key supporting technology.
2026-02-07
According to a report by the People's Daily, on February 7, China launched a reusable experimental spacecraft from Jiuquan (carried by a Long March-2F carrier rocket), which has achieved... Reusable, high-temperature resistant, lightweight, and highly reliable. among the core requirements, Metal 3D printing technology Serving as a critical support, these technologies are primarily applied to core components such as rocket propulsion systems, spacecraft thermal management/thermal protection systems, and core structural parts. All of these applications have undergone targeted technological optimizations specifically tailored to meet the requirements of reusable operational conditions. Below is a summary of the core 3D printing technologies, materials, and application scenarios that have been successfully implemented:
One, Long March-2F Launch Vehicle: 3D Printing Focuses on Propulsion Systems and Lightweight Structures, Catering to the Needs of Rocket Reusability and High Reliability.
As the launch vehicle for this mission, the core components of the Long March-2F have already been put into large-scale application. Metal Additive Manufacturing (3D Printing) Technology, with a focus on solving rocket engine issues. Thermal-end component resistance to thermal fatigue, lightweighting of structural components, and integrated molding of complex parts. The issue lays the foundation for multiple rocket launches and reusable recovery.
3D Printing Integrated Forming Technology for Engine Thrust Chambers
Adopt Selective Laser Melting (SLM) Metal 3D printing technology enables the integrated manufacturing of rocket engine thrust chambers—including combustion chambers and nozzles—in a single piece, replacing the conventional spinning + welding process. This technology, now in mass production by China’s leading enterprise, Polyt, can reduce the structural weight of thrust chambers by 20% to 30%, shorten the production cycle by more than 80%, and eliminate weld-induced weak points, significantly enhancing the engine’s performance during repeated start-up and shutdown cycles. Thermal shock resistance and fatigue resistance Adapting to the power system requirements of reusable rockets.
Send Powder Forming Technology for 3D Printing of Motive Hot-End Components
Matching Low-oxygen spherical copper alloy powder, high-temperature alloy powder 3D printing is employed, using CuCrZr copper alloy powder (with oxygen content ≤100 ppm) to print core hot-end components such as thrust chambers and gas valves. Thanks to its high thermal conductivity, this material can rapidly dissipate the 3,000℃ high temperatures generated in the combustion chamber, and when combined with a cooling system, it keeps the wall temperature within a safe operating range. High-temperature alloy powders (such as GH4169 and GH3536) are used to print components like turbopumps and turbine disks, which not only withstand high temperatures but also maintain structural integrity, providing the necessary material support for repeated, multiple operations of rocket engines.
3D Printing Topology Optimization Technology for Lightweight Structural Components of Missile Bodies
For the non-load-bearing structural components and connecting parts of the rocket body, adopt... Topology Optimization Design for 3D Printing of Titanium Alloys By removing redundant materials while ensuring structural strength, we can achieve lightweighting of the rocket body, thereby reducing the launch payload. Meanwhile, the complex topological structures created through 3D printing can enhance the components' resistance to impact, making them well-suited to withstand the mechanical stresses encountered during rocket recovery.
II. Reusable Experimental Spacecraft: 3D-printed components support thermal management, structural lightweighting, and thermal protection systems, making them suitable for both reentry and in-orbit reuse scenarios.
The core requirement for the experimental spacecraft is: High-temperature protection during atmospheric reentry, thermal management for long-term in-orbit operations, and structural reliability during the recovery process. 3D printing technology is primarily used in thermal management components, lightweight structural parts, and supporting elements of thermal protection systems, specifically addressing the core challenges in spacecraft reuse:
3D Printing High-Thermal-Conductivity Forming Technology for Spacecraft Thermal Management Components
Adopt Low-oxygen spherical pure copper powder (oxygen content < 100 ppm) 3D-printed thermal pads, substrates, and other components for spacecraft electronic systems leverage the high thermal conductivity of pure copper to efficiently dissipate heat from onboard electronic equipment during both on-orbit operations and re-entry, thereby ensuring stable device temperatures. Meanwhile, the customized thermal structures produced via 3D printing can precisely match the complex internal layouts of spacecraft, maximizing thermal efficiency. Moreover, the corrosion resistance of these molded components helps reduce maintenance costs after spacecraft recovery.
3D Printing Technology for Lightweight Structural Components of Spacecraft
For the internal supports, connecting structures, and other components of spacecraft cabins, adopt... Titanium alloy / Stainless steel 3D printing Through integrated molding, complex structures can be rapidly manufactured. Combined with topology optimization design, this approach further reduces weight, making it well-suited to meet the payload requirements for spacecraft’s round-trip missions between Earth and space. The high consistency of 3D-printed components also ensures structural stability during multiple reuse cycles of the spacecraft.
3D Printing Technology for Manufacturing Supporting Components of Thermal Protection Systems
When a spacecraft reenters the atmosphere, its surface temperature can exceed 2,000℃. Its thermal protection system... Supporting structural components, thermal insulation layer connectors Manufactured using 3D printing technology, this component is made from high-temperature-resistant ceramic matrix composites or titanium alloys. Through 3D printing, it achieves precise shaping of complex, non-standard geometries, perfectly conforming to the curved surface design of the thermal protection layer. At the same time, it ensures that the connecting structure maintains excellent high-temperature resistance and ablation resistance, providing structural assurance for the repeated use of the thermal protection system.
Three, Core technology types and aerospace compatibility of 3D printing in this mission.
The 3D printing technologies used in the spacecraft and rocket for this launch are all specifically tailored for aerospace applications. High reliability, high-temperature resistance, and reusable The specialized technologies for this demand, which differ from conventional industrial 3D printing, have the core technical parameters, features, and compatible applications as shown in the table below:
Four, The Core Value of 3D Printing Technology in Spacecraft Reusability Scenarios
The application of 3D printing technology to this reusable experimental spacecraft and the Long March-2F rocket is not merely a “simple process substitution”; rather, it is— Manufacturing solutions tailored for aerospace reusable technologies Its core values are reflected in three aspects:
Adapting to reusable performance requirements:
3D printing’s integrated molding eliminates weld seams; topology optimization enhances structural strength; and specialized powders ensure the material’s high-temperature resistance and high thermal conductivity—addressing, from both process and material perspectives, the challenges faced by aerospace equipment. Repeatedly start/shut down, re-enter high temperatures, and recover from impacts. The issue of performance degradation under repeated-use conditions is a key manufacturing technology for enabling the reuse of aerospace equipment.
Achieving cost reduction and efficiency improvement in aerospace equipment:
3D printing has reduced the production cycle of core components—such as rocket engine thrust chambers and spacecraft thermal management parts—by more than 80%. Material utilization has increased from less than 30% in conventional processes to over 95%. At the same time, it significantly lowers the R&D and manufacturing costs of complex components, aligning perfectly with the core goal of reusable spaceflight: “low cost and high frequency.”
Supporting Design Innovation in Aerospace Equipment:
The high design freedom offered by 3D printing enables aerospace equipment to... Cooling channel conformal design, customized thermal management structure design, and topology-optimized lightweight design. This has made it possible to break through the design bottlenecks of traditional manufacturing processes, providing manufacturing support for subsequent performance upgrades of reusable aerospace equipment—such as engines with greater thrust and lighter spacecraft.
Four, The Core Value of 3D Printing Technology in Spacecraft Reusability Scenarios
The 3D printing technologies and products used in this mission were all independently developed and mass-produced by domestic enterprises, forming a complete industrial chain centered around key supporting entities.
Leading 3D printing manufacturer:
Politec, the world’s only company to have achieved mass production of 3D-printed rocket engine thrust chambers, holds a 100% market share in the delivery of commercial aerospace rocket components.
Leading supplier of powders for 3D printing:
Youyan Powder Materials is a leading supplier of low-oxygen copper alloy powders, high-temperature alloy powders, and titanium alloy powders. Its CuCrZr copper alloy powder has been recognized as a high-quality additive manufacturing product by the national authorities.
Leading provider of 3D printing materials:
Sri New Materials (3D printing technology for nano-crystalline copper alloy inner walls) and Steel Research High-Tech (third-generation nickel-based single-crystal high-temperature alloy 3D-printing powder) respectively enhance the high-temperature resistance of engines and the strength of hot-end components.
Summary
In this mission involving the reusable experimental spacecraft and the Long March-2F rocket, 3D printing technology has been... Prototype manufacturing Comprehensive approach Engineering and mass-production applications Moreover, all core technologies and materials have been localized.
Its core value lies in its ability to perfectly meet the demands of aerospace reusable equipment—high temperature resistance, fatigue resistance, lightweight design, and high reliability—through integrated molding, specialized powder manufacturing, and topology optimization design. As such, it has become one of the key manufacturing technologies enabling China to achieve a low-cost space transportation system for round-trip missions and the peaceful utilization of space.
In the future, as reusable aerospace equipment becomes practical, 3D printing technology will further advance toward... Multi-material integrated printing, large-scale structural part printing, and thermal protection/electronic function integrated printing. Upgrade the direction to further drive breakthroughs in aerospace equipment performance and reduce costs.
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