Bengaluru, June 1, 2024— In a landmark achievement, the Indian Space Research Organization (ISRO) and Wipro 3D have successfully manufactured a 3D-printed rocket engine, the PS4, set to power the fourth stage of the Polar Satellite Launch Vehicle (PSLV). This breakthrough, praised by Dr. V. Narayanan, Director of Liquid Propulsion Systems Centre (LPSC) at ISRO, signifies a paradigm shift in space manufacturing, heralding the era of additive manufacturing for space exploration.
The PSLV, ISRO’s reliable launch vehicle for earth observation and scientific satellites, depends on its fourth stage, the PS4, for precise orbital placement. This stage is vital for missions in remote sensing, oceanography, cartography, and disaster warning. The successful integration of the 3D-printed PS4 engine represents a transformative step in enhancing the PSLV’s capabilities.
Traditionally produced through conventional machining and welding, the PS4 engine was radically redesigned using Design for Additive Manufacturing (DfAM) and Laser Powder Bed Fusion (LPBF) technology. The collaboration between Wipro 3D and ISRO led to the consolidation of multiple intricate components into a single, unified production unit, thereby improving production efficiency and structural integrity.
“Wipro 3D’s expertise in Additive Manufacturing has been instrumental in realizing our vision for sustainable space exploration,” stated Dr. Narayanan during his visit to Wipro 3D’s facility. “The successful integration of the 3D-printed PS4 engine into our mission marks a significant milestone for ISRO and sets new standards of advanced manufacturing in the space industry.”
Yathiraj Kasal, GM & Business Head of Wipro 3D, expressed his enthusiasm about the collaboration: “We’re honored to collaborate with ISRO on this pioneering project, highlighting the potential of advanced manufacturing in space. This partnership not only advances ISRO’s ‘Make in India’ initiative but also promotes domestic innovation and manufacturing.”
The 3D-printed PS4 engine features integrated complex cooling channels, demonstrating a commitment to sustainability and efficiency. Rigorous testing at ISRO Propulsion Complex in Mahendragiri confirmed its exceptional performance, meeting all design safety and efficiency standards.
This achievement underscores a significant advancement in the use of additive manufacturing in space exploration, positioning ISRO and Wipro 3D at the forefront of technological innovation. The successful development and integration of the 3D-printed PS4 engine mark a pivotal moment in the journey toward more efficient and sustainable space missions.
