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Western Australian metal additive manufacturing company Aurora Labs Limited has announced a Novel Engine Project update for their work with the Australian Defence Force.
Under the May update, Aurora Labs Limited (A3D) announced the completion of a first phase engine design freeze and hardware, which is now being printed for the initial test and development phase of the program.
The company had previously been engaged in a $319,000 contract by the Australian Department of Defence to develop an aircraft propulsion system using advanced 3D metal printing technology.
The contract was expected to build on ongoing development of A3D’s existing range of micro gas turbines and support defence operations utilising unmanned aerial systems platforms.
Under the contract, the company was directed to enable rapid prototyping to accelerate Defence innovation, retain intellectual property rights for potential future commercialisation opportunities and strengthen sovereign defence capabilities with Australian-designed and manufactured technology.
“Successful completion of this phase represents a major step towards sovereign production of an affordable, 3D-printed propulsion system for Defence applications,” according to an ASX announcement from Aurora Labs.
“A3D is pleased to update shareholders on the significant progress made on the Australian Department of Defence contract for a novel propulsion system targeting low fuel consumption, addition of further printed components (including our AU2 and AU4 products), and using Ti-5 printing materials for critical components.
“Building on the momentum and award of the $319,000 Defence innovation contract, the company has reached the critical design freeze milestone for a next-generation propulsion system.
“This achievement not only underscores A3D’s technical excellence but also marks a significant strategic step forward in advancing the company’s understanding of printed propulsion systems while fulfilling key contractual deliverables.
“As stipulated under milestone 1 of the contract, the design phase includes completion of engine design engineering, establishment of a test cell with integrated sensor systems … (and) procurement of long lead manufacturing items.
“Aurora Labs has satisfied the procurement obligations and has conducted comprehensive design activities, including internal reviews and engineering analysis of modelled designs through computational optimisation and performance analysis.
“In accordance with the contract requirements, a formal design review involving Commonwealth government representatives’ specialists has been completed, to formally confirm the design parameters.
“Aurora Labs has successfully completed initial additive manufacturing printing trials on the complex engine geometry. Early results have achieved density levels between 99.6 per cent and 99.8 per cent for printed components, highlighting the capability of the company’s laser powder bed fusion print technology for producing high-integrity, mission-specific aerospace components. In producing this geometry, A3D is increasing its understanding of local, sovereign capability to deliver complex aerospace components, which are not currently manufactured in Australia.
“This update demonstrates that A3D is progressing in accordance with the project schedule. Following this milestone, we will proceed immediately to fabrication and testing activities, leading towards validation trials as outlined in milestones 2 and 3, respectively.
“In addition to the company’s existing portfolio of micro gas turbine propulsion systems (AU2 and AU4 models), A3D remains committed to delivering an innovative sovereign 3D printed propulsion engine solution capable of supporting unmanned aerial systems and unmanned aerial vehicles (UAS, UAV’s) and Defence applications, consistent with the broader aims of Australian Defence Force strategic initiatives and is closely aligned with the Australian government’s emphasis on fostering innovation, enhancing workforce skills and advancing additive manufacturing technologies within the sector.
“The development of sovereign propulsion capabilities, such as the leading edge A3D novel engine, supports the objectives outlined in the Australian Guided Weapons and Explosive Ordnance (GWEO) Plan, which aims to bolster domestic missile manufacturing and long-range strike capabilities.
“Furthermore, this initiative complements Australia’s commitments under AUKUS Pillar 2, which focuses on the development of advanced capabilities including hypersonic and counter-hypersonic technologies, electronic warfare and autonomous systems. By investing in these areas, the government seeks to enhance the Australian Defence Force’s ability to defend the nation and its interests, while also contributing to regional stability and security.”
