ISRO and Wipro 3D Launch New Era of Space Exploration with 3D-Printed Rocket Engine

The Indian Space Research Organisation (ISRO) has partnered with Wipro 3D to achieve a groundbreaking feat: the development of a 3D-printed rocket engine. This innovation, named the PS4 engine, is poised to power the fourth stage of the Polar Satellite Launch Vehicle (PSLV), a cornerstone of India's space program.

PSLV: A Workhorse Takes Flight with New Technology

The PSLV is ISRO's dependable launch vehicle for deploying Earth observation and scientific satellites into orbit. The fourth stage, the PS4, plays a critical role in achieving precise orbital placement for these satellites. Missions focusing on remote sensing, oceanography, cartography, and disaster warning all rely heavily on the successful operation of the PS4. The integration of the 3D-printed PS4 engine marks a transformative step in enhancing the PSLV's capabilities and ensuring the continued success of these vital missions.

From Traditional Methods to Additive Manufacturing

Previously, the PS4 engine was manufactured using conventional techniques like machining and welding. However, through a collaborative effort, ISRO and Wipro 3D embarked on a redesign process. Leveraging Design for Additive Manufacturing (DfAM) principles and Laser Powder Bed Fusion (LPBF) technology, they revolutionized the PS4's construction.

Efficiency and Innovation: A Single, Unified Engine

This innovative approach resulted in the consolidation of numerous complex components into a single, unified engine. This not only streamlines the production process but also enhances the structural integrity of the PS4 engine.

Collaboration for the Future of Space Exploration

The success of this project highlights the potential of 3D printing technology in space exploration. Dr. V. Narayanan, Director of the Liquid Propulsion Systems Centre (LPSC) at ISRO, lauded Wipro 3D's expertise in additive manufacturing, acknowledging its role in realizing ISRO's vision for sustainable space exploration. He further emphasized the significance of this collaboration, stating that "The successful integration of the 3D-printed PS4 engine...sets new standards of advanced manufacturing in the space industry."

Yathiraj Kasal, GM & Business Head of Wipro 3D, echoed Dr. Narayanan's enthusiasm. He expressed his pride in collaborating with ISRO on this pioneering project, highlighting its potential to propel advancements in space exploration through additive manufacturing. Kasal further emphasized how this partnership not only supports ISRO's "Make in India" initiative but also fosters domestic innovation and manufacturing capabilities.

Efficiency and Performance: A Promising Future

The 3D-printed PS4 engine boasts a design that incorporates complex cooling channels, reflecting a commitment to both sustainability and efficiency. Rigorous testing conducted at ISRO's Propulsion Complex in Mahendragiri confirmed its exceptional performance, verifying that the engine meets all the designated safety and efficiency standards.