A Redesigned and 3D Printed Rocket Bulkhead

The objective of this project was to create a bulkhead with maximized consolidated parts and minimized overall part length. The University of Waterloo’s rocketry team collaborated with MSAM to utilize additive manufacturing (AM) technology in the printing of the re-designed bulkhead, which could not have been achieved with conventional manufacturing methods.

The rocketry team’s goal was to integrate several injector section systems into the bulkhead to allow for a more compact and efficient assembly. To implement this plan, AM was chosen as a method that could provide the necessary integration of complex geometries such as internal fluid passages. The team also utilized a printable BCC (Body-Centered Cubic) lattice to increase weight savings without jeopardizing structural integrity. This design allowed for the buckling load factor to triple, meaning that the bulkhead was significantly less susceptible to deformation.

Sectioned bulkhead showing internal channels, chambers, and lattice structure.

The bulkhead was successfully printed with the consolidation of at least 20 parts from the pneumatic and oxidizer fluid systems. With the use of AM processes, the elimination of heavy parts is possible, creating a notable reduction in weight and size allowing for simpler assembly and maintenance of the rocket. The bulkhead was printed within the MSAM facility using an LPBF (Laser powder bed fusion) machine and AlSi10Mg powder.

(Top) Original bulkhead assemby with various component. (Bottom) Redesigned, consolidated AM assembly.