Engineers at the National Manufacturing Institute Scotland (NMIS) have demonstrated how cold spray additive manufacturing could be used for the production of copper rocket nozzles.
According to NMIS senior technologist Calum Hicks, the project "marks an important milestone in demonstrating how advanced manufacturing can be applied to complex rocket engine components" by offering new approaches to thermal management structures, reduced development times and improved production efficiency.
The Institute's engineers have developed a hybrid manufacturing approach centred on high-pressure cold spray technology, which deposits copper in a solid state at a rate of up to 10kg per hour, and was used to build the main nozzle structure with intricate cooling channels. The team says this demonstrator part highlights the potential for high-pressure cold spray to 'transform how large copper parts are manufactured' by reducing material waste and lead times from months to days.
The method is yet to be validated through full rocket engine testing but is also thought to be a viable solution for repair applications, and other high-value sectors including aerospace, energy and shipbuilding, where robust and corrosion-resistant materials are critical.
Ryan Devine, senior research and development engineer at NMIS, said: “The real value of this work is in showing how advanced manufacturing can move beyond experimentation into practical application. By combining engineering expertise with innovative processes such as high-pressure cold spray, we’re enabling manufacturers to rethink how complex components are designed, produced and maintained. Taking these steps allows us to support faster development cycles and more resilient manufacturing systems.”
