Thermo-Calc Solutions Enables Development of 44% Lighter Multi-Material Rocket Component

Thermo-Calc Solutions contributed to a major milestone in multi-material additive manufacturing: a functionally graded nickel-titanium rocket propulsion component that was approximately 44% lighter and remained crack-free following successful hot-fire testing. As reported in Skyrora’s published test results, the campaign used a 3.5 kN low Earth orbit engine and involved six live firings of the component. Developed within the European MADE-3D project, Thermo-Calc Solutions designed the graded material transition and guided its experimental validation, while Skyrora translated the material concept into a redesigned, additively manufactured component and validated its performance under representative firing conditions.

The Nickel–Titanium Joining Challenge

Nickel alloys are used in rocket propulsion systems where high-temperature strength and thermal stability are required, while titanium offers low density and excellent strength-to-weight performance. However, joining nickel and titanium alloys by additive manufacturing or welding is challenging because detrimental intermetallic phases can form where the alloys meet, potentially leading to catastrophic cracking during fabrication. Overcoming this incompatibility required the development of a carefully designed transition that could provide a robust metallurgical pathway between the two materials.

Designing the Material Transition

Thermo-Calc Solutions applied Integrated Computational Materials Engineering (ICME) to address the challenges of joining nickel and titanium alloys. The team identified the metallurgical mechanisms responsible for cracking and designed a functionally graded material system with targeted intermediate compositions, creating a controlled transition between the two otherwise incompatible alloys. Experimental results were carefully analyzed using computational tools, to better understand the observed microstructures and guiding subsequent manufacturing iterations. By focusing experimental efforts on the most promising material solutions, this ICME-driven approach minimized trial and error and enabled the solution to be developed in less than three and a half years, while reducing experimental effort, cost and technical risk.

From Materials Design to Hot-Fire Testing

Skyrora translated the developed material solution into propulsion hardware, manufacturing the Ni-Ti multi-material component and successfully demonstrating its performance through six live firings of a 3.5 kN low Earth orbit engine at its Midlothian facility. Inspections carried out before and after the hot-fire campaign found no damage to the modified component, validating its performance under extreme operating conditions and demonstrating the viability of the multi-material manufacturing approach. By reducing component mass by approximately 44%, the breakthrough creates new possibilities for lighter and more efficient propulsion systems, marking a major milestone for European launch capability and helping bring sovereign access to space one step closer. Read the full Skyrora press coverage.

For More Information About this Project, Please Contact:

Thermo-Calc Solutions AB
John Aristeidakis

Email: info.solutions@thermocalc.com

About Thermo-Calc Solutions

Based in Stockholm, Sweden, Thermo-Calc Solutions offers specialized ICME solutions such as materials design, alloy composition, and heat treatment optimization. As the engineering services division of Thermo-Calc Software, the company serves clients globally in accelerating materials innovation through simulation and modelling.

About Skyrora Ltd

Skyrora Ltd is headquartered in Scotland, with facilities across Europe. The company designs, manufactures, and deploys launch vehicles for small satellite manufacturers seeking access to space. Skyrora’s strategy is to take an incremental, step-by-step approach that allows for critical testing and risk reduction, combining proven technology with advanced additive manufacturing methods. In August 2025, Skyrora received its launch license to commence a commercial orbital launch program.

About Made-3D

MADE-3D (Multi-Material Design using 3D Printing) was a Horizon Europe project (101091911) coordinated by Paderborn University. From January 2023 to June 2026, the project explored how multiple materials can be combined in additively manufactured components for demanding applications. See Thermo-Calc Solutions’ LinkedIn post and the MADE-3D fire-test post and footage for more from the project.