Space propulsion, rocket nozzle design and manufacturing

Space technology spin-offs give your company high-tech competences that will benefit your overall performance.

Getting Europe into space

For three decades, we have participated in setting new standards for space technology to be used in upstream applications. We are mainly working through assignment from ESA, the European Space Agency, and directly under their allied partners.

Our contribution has accomplished great success in the European space and aerospace industry. Our highly visible flagship result is participating in the development and manufacturing of a generic novel active regenerative cooled rocket nozzle design for the next-generation launchers.

The nozzle design has been implemented on the new Ariane 6 heavy lift launcher, which took its successful maiden flight 9. July 2024.

The nozzle production now continues in Sweden at our long-term partner to which we have delivered a patented x-ray guided laser welding system for the automated production.

While being the workhorse on Ariane 6, the design concept is now being optimised for future reusable launchers.

The propulsion industry constantly focusses on increased performance at a lower cost. Additive manufacturing is one of the key technologies being adapted for complex mission-critical parts. In this domain FORCE Technology has taken a leading role in the development of 3D CT scanning methods based on high energy X-ray sources. The technology has passed proof-of-concept and we have now been awarded a new development programme to demonstrate the technology by designing and manufacture an automated NDI system to the all-new Orbex Prime launcher.

Working in the space business sets the toughest requirements on performance, quality and reliability. Our contribution focuses on development, demonstration, manufacturing, and compliance testing within our key competences:

non-destructive inspection (NDI)
additive manufacturing (AM) and laser welding (LBW)
sensor technology
automation
materials characterisation
electronics testing and certification

Through our involvement in the European space business, we are literally participating in getting Europe into space.

Did you know...

That 14 tons of fuel passes through the nozzle per minute and that it is in use for only 10 minutes?

The launcher is a unique machine, which has to work first time with limited testing and is only used once. A full-scale test of the new sandwich nozzle was successfully performed late 2009.

Did you know...

That the nozzle has to withstand thrust from an engine of 150 tonnes, equal to 6 million horsepower, and burning exhaust gasses that reaches 3500^o C?

The nozzle itself must not exceed a temperature of 700^o C.

Space technology spin-off and your business

Our innovation comes from working on one of the most difficult domains in the world. We use space as a foundation for process and technology development and offer expertise concentrated on electronics testing and certification, NDI, AM, LBW, sensor technology all of which often applies in an automated context.

Integrating space technology can give your business high-tech competences and benefit your overall performance, e.g. reduce costs, enhance production or inspection speed.

If your project could benefit from these technologies, we are very interested in working with you. We offer to deliver in all steps from the development phases such as concept study, prove of concept, demonstration, delivery of equipment, turnkey systems, support, training, and technology transfer.

Ariane 6 - The rocket nozzle ready for testing

Designing the nozzle for the Ariane rocket

Our involvement in the space adventure began in 1996 with an objective set by the European Space Agency (ESA). ESA asked for a new nozzle concept in order to maintain their leading position in nozzles for rocket engines. The new design concept should be scalable to various engines, reduce production costs and shorten lead time without compromising reliability.

During the concept discussions, there was a unique opportunity to introduce new process technologies that would present a breakthrough in design never made possible before. Furthermore, improved process repeatability and robustness was achieved by introducing more machine-controlled processes in the manufacturing and quality control of nozzles.

The Ariane 6 project

We have been involved in the evolution of the main engine of the Ariane 6 rocket. The project has been setting even higher standards for increased thrust, reliability, flexibility, shorter lead-time and reduced costs. A challenge that perfectly suited our broad range of competences and ability to combine them for specific purposes that without doubt will be of benefit to other industry sectors.

Laboratory and production facilities

At our headquarters near Copenhagen, Denmark, we have established laboratory and production facilities, equipped with state of the art equipment.

Our facilities include:

lasers of different types and sizes; disk, fibre and CO₂
an automated and highly flexible weld cell, capable of handling up to 5 tons
a unique Seamtracker for sandwich designs, using X-ray vision to guide the laser welding tool
a broad range of X-ray and ultrasonic equipment, including a dedicated installation for automated inspection of full size nozzles.

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Reach out to Thomas Aaboe Jensen for more information.