Skyrora successfully completes hot-fire testing of advanced LEO engine developed through European manufacturing programme
UK launch services company Skyrora has successfully completed a hot-fire test campaign of its 3.5kN LEO engine featuring an advanced titanium-coated component developed through the European Union-funded MADE-3D programme, marking a significant milestone in the development of next-generation manufacturing technologies for the space sector.
The test campaign, carried out at Skyrora's Midlothian testing facility, achieved its planned technical objectives and concludes the company's work within the international MADE-3D consortium, a Horizon Europe project bringing together leading research organisations and industrial partners to advance multi-material additive manufacturing for space applications.
The modified engine incorporated a newly developed titanium-coated component designed to improve performance in the demanding thermal environment experienced during rocket engine operation. The titanium layers were deposited using the Skyprint 2 hybrid DED 3D printer, developed in-house at Skyrora.
Replacing the nickel-based alloy with a titanium alloy in rocket engine components enables a weight reduction of approximately 44%, opening up significant potential for lightweight design in aerospace.
X-ray inspections conducted before and after the six fire tests revealed no damage within the modified engine components, confirming their excellent performance under high temperatures and loads. The successful test validated the manufacturing approach and its suitability for future propulsion systems.
Unlike conventional manufacturing methods, the technologies explored through MADE-3D enable components to be produced using multiple materials within a single manufacturing process, allowing engineers to optimise different sections of a component for strength, weight and thermal performance. For launch vehicles, these advances could reduce manufacturing complexity while improving overall engine efficiency and performance.
Jordan McCormick, Design and Test Engineer at Skyrora, said: "One of the biggest challenges in advanced manufacturing is moving promising technologies beyond the laboratory and proving that they can perform in real operating environments. Successfully completing this hot-fire campaign is an important demonstration of that process.
Through MADE-3D, we've worked alongside outstanding European partners to explore new approaches to additive manufacturing that could reshape the design and manufacture of propulsion systems. Bringing those innovations into a functioning rocket engine and testing them under live firing conditions represents an important milestone for both the consortium and Skyrora."
Throughout the MADE-3D programme, Skyrora has contributed its expertise in rocket propulsion, additive manufacturing and engine testing to help demonstrate how advanced manufacturing techniques can be applied to complex aerospace hardware.
The consortium's work aims to accelerate the adoption of innovative manufacturing technologies across Europe's space sector, supporting the production of lighter, more efficient and more resilient components for future launch systems and spacecraft.
The successful completion of the hot-fire campaign closes Skyrora's technical contribution to the MADE-3D project while providing knowledge to inform the future development of the company's propulsion technologies.
