LEAP 71 reveals ambitious plans for meganewton-class rocket engines leveraging advanced computational methods and industrial 3D printing.
Dubai-based LEAP 71 has launched a new initiative in its rocket development program, shifting focus to powerful meganewton-class propulsion systems for space exploration.
The initiative centers on two advanced engine configurations: a 200 kN aerospike and a 2000 kN bell-nozzle design, both evolving from the company’s earlier research with lower-thrust systems.
“We’re approaching these different engine types as variations stemming from unified computational principles,” said Josefine Lissner, Managing Director at LEAP 71. “This integrated strategy allows us to explore diverse architectures while maintaining developmental consistency.”
The firm combines sophisticated computational engineering with next-generation 3D printing to develop intricate propulsion solutions tailored for upcoming space expeditions.
Manufacturing Breakthroughs
LEAP 71 has achieved significant progress in large-scale metal Additive Manufacturing technology, now capable of fabricating components larger than 1.5 meters. This breakthrough enables direct production of substantial engine parts at full operational scale.
Previous project showed feasibility by printing the compact 5 kN aerospike engine in one piece made from copper. The modern projects build on this base, with such complex components as the 600 mm injector and follow up sea-level nozzle in XRB-2E6 requiring fabrication equipment of around 1600 mm of vertical dimension.
This manufacturing strategy significantly decreases component quantities, removes assembly complexity, and streamlines production tolerances and finishing operations.
Strategic Development Timeline
Despite technological advances, LEAP 71 Co-Founder Lin Kayser recognizes significant challenges ahead. “Converting digital designs to functional test hardware remains our greatest hurdle,” Kayser noted during a recent briefing.
The program has a systematic development plan, first emphasizing less advanced gas generator cycles in order to establish basic technologies. Testing of the XRA-2E5 aerospike is expected to start within 18 months, while the more advanced XRB-2E6 bell-nozzle engine with full-flow staged combustion will be completed by 2029.
“While we’re undertaking a lengthy development process, our rapid progress with computational tools and modern fabrication methods shows tremendous promise,” explained Lissner.
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LEAP 71 continues to establish partnerships with Additive Manufacturing specialists to validate large-scale production techniques and engages with aerospace industry clients to transform conceptual designs into flight-certified propulsion systems for orbital deployment.
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