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Amt Project Justify
Amt Project Justify
Submitted to
Sir. Syed Hassan Shah
By
Ahmed Hassan Tariq
BME203018
Of the degree of
Islamabad
All rights reserved. Reproduction in whole or in part in any form requires the prior written
permission of
BME203018
2
DECLARATION
It is declared that this is an original piece of my own work, except where otherwise
acknowledged in text and references. This work has not been submitted in any form for
another degree or diploma at any university or other institution for tertiary education and
shall not be submitted by me in future for obtaining any degree from this or any other
University or Institution.
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Abstract
This research examines the state-of-the-art manufacturing methods used by SpaceX, a major
aerospace operator, and assesses how well these methods match with the Sustainable
Development Goals (SDGs) of the United Nations. An outline of SpaceX's past development,
present position in the aerospace industry, and dedication to sustainability and innovation is
provided at the outset of the study.
Examining applications, benefits, and related issues, the research investigates advanced
manufacturing processes and looks at additive manufacturing (3D printing) as a means of
making rocket components. The integration of automated manufacturing processes is also
examined, with a focus on the effects of robots and automation on improvements in efficiency
and precision.
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Table of Contents:
Contents
Chapter 1: Introduction ....................................................................................................................... 7
1.1: Background .............................................................................................................................. 7
1.2: Purpose of the project.............................................................................................................. 7
1.3: Scope and Significance ............................................................................................................ 7
Chapter 2: SpaceX Overview ............................................................................................................... 8
2.1: History and Evolution ............................................................................................................. 8
2.2: Current Status in Aerospace Industry.................................................................................... 8
2.3: Innovation and Sustainability ................................................................................................. 9
Chapter 3: Advanced Manufacturing Techniques ............................................................................ 10
3.1: Overview................................................................................................................................. 10
3.2: Additive Manufacturing (3D Printing) ................................................................................. 10
3.2.1: Applications in Rocket Components: ................................................................................ 11
3.3: Automated Manufacturing Processes ................................................................................... 13
3.3.1: Robotics and Automation in Production:........................................................................... 13
Chapter 4: Material Science and Selection ....................................................................................... 14
4.1: Carbon-fiber Composites ...................................................................................................... 14
4.2: Aluminum-Lithium Alloys .................................................................................................... 14
4.3: Overall Benefits...................................................................................................................... 15
Chapter 5: Alignment with Sustainable Development Goals (SDGs) ............................................... 16
5
Table of Figures:
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Chapter 1: Introduction
1.1: Background
In an effort to achieve innovation, efficiency, and sustainability, the aerospace industry has
undergone a radical transition towards advanced production techniques. Using cutting-edge
technology to revolutionize space travel, Elon Musk's SpaceX is at the vanguard of this
transformation, having been formed in 2002. The company is now at the forefront of
developing and using the latest advanced manufacturing techniques to manufacture the
components used in their rocket ships.
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Chapter 2: SpaceX Overview
In 2017, focus switched to developing Starships for interplanetary travel. Test failures were
one of the hurdles, while Crew Dragon missions for NASA's Commercial Crew Program were
among the successes. SpaceX conducted testing of the Starship prototype, boosted its launch
frequency, and was a key player in NASA's Artemis program.
Additionally, SpaceX has contributed hardware and knowledge for lunar exploration missions
to NASA's Artemis program, which has been extremely important. Due to the company's
inventions, SpaceX is now a leader in the quickly changing aerospace sector, particularly with
regard to the ongoing development of rocket technology and propulsion systems.
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2.3: Innovation and Sustainability
Under Elon Musk's direction, SpaceX innovates by pushing the limits of technology and
redefining aerospace standards. Fundamental to its philosophy is a dedication to sustainability,
which is best shown by the revolutionary reusable rocket technology. In line with its mission
of accessibility and economic feasibility, SpaceX has revolutionized space travel economics
by landing and reusing rocket stages. Reusing components, recycling them, and looking into
eco-friendly materials are just a few of the ways that operations include sustainability.
In addition to cutting costs, SpaceX prioritizes the integration and use of renewable energy
sources into its operations, demonstrating a commitment to lowering its carbon footprint. New
and bold endeavors like as the Starship spaceship serve as prime examples of SpaceX's long-
term strategy for sustained interplanetary travel.
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Chapter 3: Advanced Manufacturing Techniques
3.1: Overview
The application of cutting-edge, innovative, or advanced technology to enhance goods or
procedures is known as advanced manufacturing. Modern technology and procedures used in
advanced manufacturing transform conventional production methods. One of the most
important elements is additive manufacturing (3D printing), which uses layer-by-layer building
to create complex patterns. Automation improves accuracy and consistency in industrial
processes, from assembly to quality control, and is powered by robotics and artificial
intelligence [1].
Materials science, which emphasizes lightweight materials like carbon fiber composites and
sophisticated alloys, is essential. Reusability and recycling are two practices that are included
into the focus of sustainability. Green manufacturing techniques and the incorporation of
renewable energy sources are combined with a focus on energy efficiency.
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Figure 3: Schematic Diagram of DMLS Process [10]
Materials: The Merlin engines, which power the Falcon 9's first stage, incorporate 3D-printed
components. The primary material used in these engines is a high-strength alloy known as
Inconel, which can withstand the extreme temperatures and pressures during rocket propulsion.
Temperatures: Rocket engines experience extreme temperatures during launch and re-entry.
Inconel, with its exceptional heat resistance, is well-suited for the combustion chambers and
nozzles where temperatures can exceed 3,300 degrees Fahrenheit (1,815 degrees Celsius).
Advantages: 3D printing allows for the creation of intricate and complex geometries that would
be challenging or impossible with traditional manufacturing methods. This precision in design
contributes to optimal engine performance.
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Falcon 9 Rocket: Main Oxidizer Valve
In a rocket engine, the main oxidizer valve is a crucial component responsible for regulating
the flow of oxidizer into the combustion chamber. The main oxidizer valve controls the rate at
which oxidizer is injected into the combustion chamber, allowing for precise control of the
combustion process and, consequently, the thrust generated by the rocket.
In August of 2014, it was revealed by Elon Musk himself that they had used 3D manufacturing
to construct the main oxidizer valve that was used in the Falcon 9’s rocket engine. The
component was also constructed in a record-breaking time of 2 days, compared to a time of at
least 2 months had they used conventional manufacturing techniques like casting [7].
SuperDraco Engines:
Thruster Components: Other components, such as the thruster heads and valves, also
incorporate 3D-printed parts made from materials capable of withstanding the harsh conditions
of space travel.
Advantages: 3D printing allows for the creation of intricate cooling channels within the
combustion chambers, enhancing the engine's ability to regulate temperatures and ensuring
optimal performance during critical phases of space missions.
Overall Impact:
Weight Reduction: The use of 3D printing enables the creation of lightweight yet durable
components, contributing to overall weight reduction in the rocket. This is crucial for achieving
cost-effective launches and maximizing payload capacity.
Precision and Performance: The ability to manufacture complex geometries with precision
enhances the performance of rocket engines. Optimized designs contribute to efficiency in
combustion, resulting in improved thrust and overall rocket performance.
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3.3: Automated Manufacturing Processes
Automated manufacturing processes involve the use of robotics and advanced automation
systems to carry out various stages of production without direct human intervention. Through
the integration of robotics, tasks such as assembly, welding, and quality control are performed
with a high degree of accuracy and speed. Automation not only streamlines production
workflows but also contributes to improved safety conditions by handling repetitive or
hazardous tasks. SpaceX's adoption of automated manufacturing processes aligns with the
company's commitment to innovation, allowing for increased production efficiency and the
realization of ambitious goals in space exploration.
Robotics is also used in quality control procedures. Automated inspection systems have the
ability to quickly and accurately evaluate component quality and detect any deviations from
specifications.
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Chapter 4: Material Science and Selection
The use of lightweight materials, such as carbon fiber composites and aluminum-lithium alloys,
by SpaceX is intricately linked to advanced manufacturing techniques, particularly additive
manufacturing (3D printing) and precision machining.
SpaceX uses composite materials in their rockets, primarily in the construction of the fairings
that protect payloads during launch. A fairing is the outer covering of a rocket, and its primary
function is to protect the payload from aerodynamic loads, thermal loads, and other
environmental factors during the launch and ascent phases. SpaceX's fairings are made from
carbon fiber-reinforced polymer (CFRP), which is a composite material consisting of carbon
fiber and a polymer matrix. CFRP is known for its high strength-to-weight ratio, which makes
it an ideal material for aerospace applications where weight is critical.
SpaceX decided to use an aluminum-lithium alloy for the Falcon 9 fuel tanks because it is
lightweight, strong, and has a high resistance to cracking. This makes it an ideal material for
use in fuel tanks, which need to be able to withstand the high pressures and temperatures that
occur during a rocket launch. Additionally, aluminum-lithium alloy is also less expensive than
other materials that could have been used for the fuel tanks, such as titanium [6].
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4.3: Overall Benefits
The integration and use of these lightweight materials coupled with the use of advanced
manufacturing techniques has several benefits which include:
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Chapter 5: Alignment with Sustainable Development Goals (SDGs)
The Sustainable Development Goals (SDGs) are a set of 17 global goals established by the
United Nations in 2015 as part of the 2030 Agenda for Sustainable Development. These goals
were created to address a range of interconnected global challenges and promote a more
sustainable and equitable world. The SDGs cover a wide spectrum of issues, including poverty,
hunger, health, education, gender equality, clean water, affordable and clean energy, industry
and innovation, climate action, peace, justice, and partnerships.
1. Renewable Energy Integration: SpaceX incorporates renewable energy sources into its
operations. Solar panels, for instance, are used to harness the power of the sun,
providing a clean and sustainable source of energy for various aspects of its
manufacturing facilities and operations.
2. Advancements in Reusability: A significant aspect of SpaceX's contribution to SDG 7
lies in its pursuit of reusable rocket technology. The company has successfully
developed and implemented reusable first-stage rocket boosters, as seen in the Falcon
9's capability to land and be refurbished for multiple launches.
3. Efficient Rocket Propulsion: SpaceX's development of the Falcon rockets, especially
the Falcon 9 and Falcon Heavy, emphasizes efficiency in rocket propulsion. These
rockets utilize advanced engines, such as the Merlin engines, designed for optimal fuel
efficiency and performance.
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5.2: SpaceX's Contribution to SDG 9 (Industry, Innovation, and
Infrastructure)
SpaceX significantly contributes to Sustainable Development Goal 9 (SDG 9) - "Build resilient
infrastructure, promote inclusive and sustainable industrialization, and foster innovation."
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Chapter 6: Challenges and Future Prospects
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Chapter 7: Conclusion
SDG 7 (Affordable and Clean Energy), SDG 9 (Industry, Innovation, and Infrastructure), and
SDG 12 (Responsible Consumption and Production) are among the Sustainable Development
Goals that SpaceX is leading the way in achieving through the integration of innovative
manufacturing techniques. SpaceX has demonstrated how technological breakthroughs and
ecological practices may coexist peacefully through the use of renewable energy, efficient
propulsion systems, reusable components, and ethical material selections.
The aerospace sector and global sustainability will be significantly impacted as SpaceX
develops and grows its production capacity. The company's accomplishments not only help
space exploration missions succeed, but they also establish a standard for ethical and
progressive manufacturing practices in the larger industrial sector. The aerospace industry and
beyond can draw inspiration from the lessons learnt from SpaceX's path into advanced
manufacturing, which highlights the transformative power of technological innovation when it
is in line with the values of sustainability and responsible development. Essentially, SpaceX's
narrative serves as a tribute to the potential that emerges from the marriage of stateof-the-art
technology with an unwavering dedication to environmental conservation and the quest for a
more sustainable future.
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Chapter 8: References
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limitless possibility. (2023)
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computer.com/spacex-the-complete-history/ (2023)
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manufacturing helped launch spacex, Kingsbury. Available at:
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[5] Marcin Frąckiewicz .The role of spacex in developing space manufacturing, TS2 SPACE.
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alloy-for-the-Falcon-9-fuel-tanks
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