July 4th news, from Inner Mongolia comes a heartening message: the independently developed 3D printed minimalist lightweight micro jet engine by the China Aerospace Propulsion Research Institute has successfully completed its first flight verification on the test platform, marking a milestone event that signifies significant progress in the field of aeronautical power engineering in our country.
According to "China Aerospace Propulsion," the engine used for flight verification possesses unique technical advantages. It adopts multi-disciplinary topology optimization additive manufacturing technology, achieving a revolutionary integration and innovation of aviation engine design concepts and manufacturing processes, filling the gap in domestic application of this technology. As the first 160 kg thrust level multi-disciplinary topology optimization additive manufacturing jet engine to complete flight verification domestically, its development has been the result of the efforts of many researchers.
The research team, under the careful guidance of Academician Yin Zeyong's workstation, focused on exploring cutting-edge technologies and broke through many constraints of traditional design and manufacturing. They successively overcame key technologies such as multi-disciplinary topology optimization design for additive manufacturing and integrated design of components. These technological breakthroughs not only significantly reduced the structural weight of the engine but also greatly improved key performance indicators.
In the flight verification phase, everything was strictly carried out according to the predetermined plan. The test platform reached a maximum altitude of 4000 meters above sea level, fully verifying the reliability and stability of the engine under real flight conditions. The successful first-time flight verification was not accidental; previously, the engine had already completed key ground tests such as overall performance compliance and overall life, making adequate preparations for the flight verification.
The successful first flight of this 3D printed minimalist lightweight micro jet engine is another important achievement of China Aerospace Propulsion in adhering to independent innovation and focusing on overcoming key core technologies, which will lay a more solid technical foundation for the subsequent development of advanced aeronautical engines and promote the development of China's aviation industry to new heights.
From the perspective of military applications, a 60kg jet engine can drive an aircraft with a takeoff weight of 500-600 kilograms, flying at hundreds of kilometers per hour continuously. Its military use scenarios are extensive. In terms of suicide drones, China may be able to manufacture low-cost suicide drones by combining this engine with 3D printing technology, launching a "swarm" attack on various targets on the "First Island Chain." Even if the attack fails, it can consume a large amount of enemy anti-aircraft ammunition. As a power system for loitering munitions, loitering munitions equipped with a 160kg jet engine may have a range of 200-400 kilometers, capable of striking enemy tanks, armored vehicles, radar stations, command centers, and other targets. At the same time, it is suitable for providing power to small reconnaissance drones, enabling them to fly at high speeds and perform battlefield reconnaissance, target monitoring, and other tasks in medium-low altitudes, quickly reaching designated areas and maintaining long-term cruising to provide real-time intelligence. Additionally, it can serve as a power unit for target drones, simulating the flight characteristics of enemy cruise missiles, fighter jets, etc., for live ammunition training or performance testing of air defense systems, improving the effectiveness of training and testing.
The application of 3D printing technology in the manufacturing of a 160kg class jet engine can significantly improve production efficiency and performance, with prominent core advantages. First, it achieves integrated manufacturing of complex structures, enhancing performance. The core components of the jet engine have complex structures, traditionally requiring multiple parts to be separated and assembled, leading to issues such as gaps and stress concentration; however, 3D printing can achieve "one-piece molding" of complex structures, reducing the number of parts by more than 90%, lowering assembly errors, optimizing internal flow channel designs, and improving combustion efficiency and high-temperature resistance. Second, it shortens the R&D and production cycle. Traditional manufacturing requires making molds and multiple processing steps, and developing a new engine may take several years; 3D printing does not require molds, directly stacking materials layer by layer based on digital models, allowing for rapid iteration after design modifications, shortening the prototype development cycle by 50%-70%, which is suitable for the rapid response needs of military equipment iterations.
Third, it has high material utilization and reduces costs. High-temperature alloys are commonly used in jet engines, with traditional processing having a material utilization rate of less than 10%, resulting in a lot of material being wasted through cutting; 3D printing, by "stacking materials as needed," can achieve a material utilization rate of over 90%, significantly reducing the consumption of expensive materials, especially suitable for the needs of "low cost and mass production" in the military field. Fourth, it is flexible in adapting to small-batch and customized demands. Military equipment often needs to adjust engine parameters according to mission scenarios; 3D printing can quickly produce customized parts by modifying digital models without redesigning the production line, avoiding high investment in traditional production lines for small-batch prototypes or special model engines, thus reducing customization costs. Fifth, it achieves lightweight design, improving the thrust-to-weight ratio. 3D printing uses topology optimization technology to "hollow out" non-load-bearing areas while ensuring structural strength, achieving component lightweighting, reducing weight by 30%-50%, which directly improves the thrust-to-weight ratio of the jet engine, enhancing the endurance and maneuverability of drones and loitering munitions.
These advantages make 3D printing technology very practical in the military field, especially in scenarios requiring rapid mass production and high-performance small power units, particularly suitable for the large-scale deployment needs of suicide drones, loitering munitions, etc. The scene of "overwhelming high-speed suicide drone attacks" may become a reality.
Original article: https://www.toutiao.com/article/7525741854462116393/
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