Ariane 6 launched with specially designed rocket nozzle

Additive manufacturing, automated X-ray-guided laser welding, and advanced sensor technologies have pushed the boundaries of what is possible in rocket nozzle design and production.

ESA’s Ariane 6 rocket has now been launched with an entirely new rocket nozzle design that significantly reduces the number of components and production time, shortens lead times, and can be adapted to different engine configurations – all without compromising reliability or operational safety.

High demands on quality, performance, and safety

Force Technology has contributed to the development of the rocket nozzle design alongside several other companies.

“The space industry places the highest demands on quality, performance, and operational reliability, while continuously requiring new and innovative solutions. It is a privilege for Force Technology to participate in this project and apply our technical expertise in such a demanding environment,” says Thomas Aaboe Jensen, Programme Manager at Force Technology.

Close collaboration with Swedish specialists

The development work was carried out in close collaboration with Sweden-based GKN Aerospace. Over time, the partnership evolved into a highly integrated technical collaboration, with Force Technology acting as a natural extension of GKN Aerospace’s development department. Ideas were exchanged continuously and often tested in practice using Force Technology’s specialised facilities.

“We have built a fully automated production system that first laser welds approximately 1,400 cooling channels in a specially developed high-temperature-resistant material and then adds the necessary reinforcement structures using additive manufacturing,” explains Thomas Aaboe Jensen.

Significant reductions in cost and material use

The rocket nozzle measures 2.1 metres in diameter at its widest point and stands 2.3 metres high. The combination of the new nozzle design and Force Technology’s manufacturing process has resulted in a 90% reduction in the number of individual components, a 40% reduction in costs and a 30% reduction in production time.

Force Technology has participated in the manufacture of the rocket nozzles for Ariane 6’s first 5 flights.