Additive manufacturing in rocket propulsion systems: a literature review

Abstract Additive manufacturing (AM), commonly referred to as 3D printing, enables the layer-by-layer construction of components and offers distinct advantages over traditional subtractive manufacturing methods. These include reduced lead times, lower material waste, cost savings and the ability to fabricate complex geometries that are otherwise difficult or impossible to achieve. These benefits have made AM particularly attractive for aerospace applications, especially in the production of rocket propulsion systems. This review examines the role of AM in manufacturing propulsion-specific components such as combustion chambers, injectors and nozzles. It highlights the advantages of part consolidation and mass reduction through optimised structural designs and provides an overview of the primary AM techniques relevant to this field. Challenges, current advancements and opportunities for future development in propulsion-related AM applications are also discussed.