Diego Pérez, Isaac Pimentel, and Nuria Hernández presented their research at the International Astronautical Congress (IAC) 2024 in Milan. Their paper, titled "Advancing Experimental Rocketry: FDM-Enabled Ceramic Nozzles for Low-Budget Experimental Propellants", explores an innovative approach to rocket nozzle manufacturing, using 3D printing with ceramic filaments.

The paper presents research on the fabrication of nozzles for experimental rockets using additive manufacturing (AM), specifically Filament Deposition Modeling (FDM), with filaments containing ceramic particles. The main goal is to develop a more cost-effective and efficient alternative for manufacturing nozzles that can withstand the high temperatures and extreme conditions associated with experimental propellants.

The work prioritizes two approaches: the creation of sacrificial molds using thermoplastic materials (such as PETG and ABS) to be filled with refractory materials, and the direct 3D printing of nozzles using ceramic filaments. Printing parameters such as fill density, printing temperature, and wall thickness were optimized to achieve the best mechanical and thermal resistance.

The tests showed that nozzles made with ceramic filaments exhibit better thermal and mechanical resistance compared to those made with PETG molds, making them suitable for larger rockets and longer combustion times. Additionally, the study suggests that this approach could facilitate rapid iterations in nozzle design for testing new propellants, reducing both production costs and times compared to traditional methods.

The paper concludes that the combination of FDM and ceramic filaments has the potential to transform nozzle manufacturing in experimental rocket projects, providing an efficient and accessible alternative to conventional metal nozzles.