The Indian Space Research Organisation (ISRO) and Wipro 3D announced a landmark partnership in space technology with the successful manufacturing of a 3D-printed PS4 rocket engine. This advanced engine will power the fourth stage of the Polar Satellite Launch Vehicle (PSLV), a critical component in deploying earth observation and scientific satellites into precise orbits. The PSLV facilitates a wide range of applications including remote sensing, oceanography, cartography, mineral mapping, and disaster warning.

To ensure precise orbital placement, the PS4 stage is equipped with state-of-the-art navigation, guidance, and control systems. Its versatility is enhanced by its capability to support multiple restarts and payload adapters, making it suitable for a variety of spacecraft missions.

Traditionally, the PS4 engine was manufactured using conventional machining and welding techniques. However, the collaboration between ISRO and Wipro 3D introduced a revolutionary redesign employing additive manufacturing technology. This method provides superior precision, minimizes resource utilization, and significantly reduces material wastage and production time.

The partnership adopted Design for Additive Manufacturing (DfAM) and Laser Powder Bed Fusion (LPBF) technology to streamline the production of the PS4 engine. By consolidating multiple components into a single unit, the new design enhances production efficiency and structural integrity.

Dr. V Narayanan, Director of the Liquid Propulsion Systems Centre (LPSC) at ISRO, emphasized the significance of this advancement, stating, "Wipro 3D's expertise in Additive Manufacturing has been instrumental in realizing our vision for sustainable space exploration. 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, General Manager and Business Head of Wipro 3D, expressed pride in the collaboration, noting, "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. We eagerly await the successful second round of testing to fly high alongside ISRO".

The 3D-printed PS4 engine features integral complex cooling channels, prioritizing sustainability and efficiency with minimal material wastage and reduced post-print machining operations. Rigorous testing at the ISRO Propulsion Complex in Mahendragiri confirmed the engine's performance, meeting all design safety and efficiency standards. The key performance metrics, including optimal chamber pressure, fuel management, combustion efficiency, and specific impulse (Isp), were validated during an extended duration test.

This successful venture underscores the potential of additive manufacturing in revolutionizing space technology, paving the way for more sustainable and efficient space exploration.