MBSE Utilization for Additive Manufactured Rocket Propulsion Components

Model Based Systems Engineering (MBSE) has garnered increased utilization among various NASA's spaceflight programs such as the Human-to-Mars In-Situ Resource Utilization (ISRU) and Cis-Lunar Habitat architectures, Commercial Crew Program (CCP), and Space Launch System (SLS). Recently, MBSE has also helped support NASA's Design-for-Reliability (DFR) and Mission Assurance activities. The utilization of MBSE helps visualize the development of the overall system in a digital environment. For the development of rocket propulsion systems, leveraging MBSE helps find ways to achieve reduction in costs, schedule, and risk throughout its life-cycle in a comprehensive and a cohesive manner. In order to deliver affordability in the competitive space race environment, it is important to reap the benefit of newer manufacturing technologies such as Additive Manufacturing (AM). In development of rocket propulsion systems, AM provides new design and performance opportunities for the rocket engine designs that is often complex. The fundamental advantage of an additively manufactured rocket propulsion element is the reduction in lead time and cost against traditional production techniques. AM designs help realize complex shapes and geometries that are often challenging and expensive to be produced using traditional production methodologies. In the context of a development of rocket propulsion system, AM provides the technological opportunity to realize newer engine designs that are technically and economically feasible. Significant efforts such as NASA's Additive Manufacturing Demonstrator Engine (AMDE) employ additive manufacturing in production of rocket propulsion engines. On the other hand, MBSE provides the ability to visualize the impact of a design change in a digital environment. Consequently, the objective of this study is to evaluate the benefits of leveraging MBSE suited to the context of additive manufactured rocket propulsion elements. A literature review is performed for the current state-of-the-art of additive manufactured rocket propulsion elements and potential opportunities to leverage MBSE has been identified. Furthermore, a design example (RS-25 or Space Shuttle Main Engine) has been explored to demonstrate the benefits of the research idea in this study. The choice of the design example is driven by the need to restart production of the engine for NASA's future launch manifests. Finally, the results of this study have been assessed qualitatively within the scope of reducing the time in Test-Fail-Fix (redesign, remanufacturing, retest, and recertification) cycle of the engine.