US 12,253,051 B2
Modulating internal ballistics in a 3D-printed rocket motor and an additive manufacturing process
Jason Hundley, Albuquerque, NM (US); Mark Kaufman, Auburn, CA (US); and Michael McPherson, Socorro, NM (US)
Assigned to X-Bow Launch Systems, Inc.
Filed by X-Bow Launch Systems Inc., Albuquerque, NM (US)
Filed on Dec. 20, 2023, as Appl. No. 18/390,025.
Application 18/390,025 is a continuation of application No. 17/325,524, filed on May 20, 2021, granted, now 11,852,101.
Claims priority of provisional application 63/049,056, filed on Jul. 7, 2020.
Claims priority of provisional application 63/027,887, filed on May 20, 2020.
Prior Publication US 2024/0117782 A1, Apr. 11, 2024
Int. Cl. F02K 9/24 (2006.01); B29C 64/314 (2017.01); B29C 64/371 (2017.01); B29C 64/386 (2017.01); B33Y 10/00 (2015.01); B33Y 40/00 (2020.01); B33Y 50/00 (2015.01); B33Y 70/10 (2020.01); B33Y 80/00 (2015.01); B64G 1/40 (2006.01); F02K 9/10 (2006.01); F02K 9/18 (2006.01); F02K 9/28 (2006.01); F02K 9/34 (2006.01); F02K 9/72 (2006.01); B29K 55/02 (2006.01); B29L 31/20 (2006.01)
CPC F02K 9/24 (2013.01) [B29C 64/314 (2017.08); B29C 64/371 (2017.08); B29C 64/386 (2017.08); B33Y 10/00 (2014.12); B33Y 40/00 (2014.12); B33Y 50/00 (2014.12); B33Y 70/10 (2020.01); B33Y 80/00 (2014.12); B64G 1/404 (2013.01); F02K 9/10 (2013.01); F02K 9/18 (2013.01); F02K 9/28 (2013.01); F02K 9/34 (2013.01); F02K 9/72 (2013.01); B29K 2055/02 (2013.01); B29L 2031/20 (2013.01); F05D 2220/80 (2013.01); F05D 2230/30 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A method of making a multi-grained fuel grain for a rocket, the method comprising:
in an additive manufacturing process:
using at least one nozzle to extrude a composite first propellant, the composite first propellant comprising the multi-grained fuel grain;
the multi-grained fuel grain forming at least one void, the at least one void facilitating variation in internal ballistics;
forming sensors, said sensors facilitating continuous monitoring and continuous modifications, to remotely control a thrust and a burning rate and a ballistics profile of a rocket motor and to indicate suitability of use over time of extended storage;
forming an electrically-controlled second propellant in contact with and operatively coupled to the sensors; and
wherein the additive manufacturing process uses the at least one nozzle with control algorithms to extrude raw materials to achieve desired deposition volumes of fuel grain forms and with temperature control of the raw materials that allows initiation of cure, the additive manufacturing process extrudes both the sensors and the first and second propellants together in a single continuously monitored, continuously modifiable additive process further comprising forming a shell around a rocket body.