Sciaky Manufactures Critical EBAM Component for Intuitive Machines’ Moon Landing

Sciaky manufactured a critical part used for Intuitive Machines’ IM-1 mission to the Moon in February 2024. This after previously printing large-scale additive manufacturing (AM) parts for land, sea, air and satellite applications. 

The part was printed with an expensive, difficult-to-deposit refractory alloy on one of Sciaky’s electron beam additive manufacturing (EBAM) systems, but it only took 16 hours to complete. The part itself is the upper section of the main engine nozzle, which provides the main source of thrust for descent. Sciaky produced two additional upper nozzle sections, which were provided to Intuitive Machines for testing. 

Intuitive Machines rigorously tested the part under hot fire testing conditions — burning fuel up to the full throttle. After the determination that the part was suitable for end-use, it was assembled into the Nova-C lunar lander, Odysseus, for the IM-1 mission. As a part of the main engine of the lunar lander, the Sciaky-made upper nozzle section performed as required in the inhospitable environment of space.  

The IM-1 Mission successfully landed the spacecraft on the Moon’s South Pole region, marking the United States’ first return since Apollo 17 in 1972 and the first commercial lunar lander to transmit valuable science data of each NASA payload from the lunar surface. The IM-1 Mission was part of NASA’s Commercial Lunar Payload Services (CLPS) initiative, which is exploring and preparing the Moon for crewed missions in the future.

The mission had a few challenges, but Intuitive Machines’ concept was proven and the main objectives of the mission were met, as the lander sent back critical data and made the case for future missions of its kind. Sciaky is actively researching ways to improve upon its contributions to the aerospace sector.

Intuitive Machines is a diversified space company focused on space exploration. It supplies space products and services to support sustained robotic and human exploration to the Moon, Mars and beyond. The company’s products and services are offered through its four business units: Lunar Access Services, Orbital Services, Lunar Data Services, and Space Products and Infrastructure.

The company says EBAM technology’s unique features provide manufacturers with a range of benefits, including reduced material waste, shorter lead times and increased design flexibility. By utilizing wire feedstock instead of powder, EBAM minimizes waste and cost, leading to significant cost savings and sustainability advantages. Moreover, the ability to fabricate near-net shape parts reduces the need for costly postprocessing and machining, optimizing production time and costs.

Sciaky’s EBAM technology has enabled manufacturers to realize complex geometries and lightweight designs that were previously unattainable using traditional manufacturing methods. With the freedom to create intricate internal structures and consolidated assemblies, engineers can now optimize part performance and reduce weight, resulting in improved fuel efficiency and enhanced overall functionality.