LEAP 71, a computational engineering firm, has entered the following section of its rocket engine program, scaling its computational engineering methodology to develop meganewton-class propulsion methods. Constructing on the profitable validation of smaller-scale engines, the corporate is now advancing two reference designs: the Noyron XRA-2E5, a 200 kN aerospike engine, and the Noyron XRB-2E6, a 2000 kN bell-nozzle engine.
Each new reference rocket motors are conceived as full propulsion methods, together with the turbomachinery required to energy them. On the core of this effort is Noyron, LEAP 71’s massive computational engineering mannequin, which encodes physics-informed logic to autonomously generate manufacturable {hardware}, with out human intervention.
“The aerospike and bell-nozzle engines we’re growing aren’t separate efforts – they’re completely different phenotypes of the identical computational DNA,” mentioned Josefine Lissner, Managing Director of LEAP 71 and principal architect of the Noyron mannequin. “This unified strategy permits us to discover basically completely different engine architectures with out reinventing the wheel each time. It’s a scientific means of scaling complexity.”
LEAP 71’s methodology combines computational engineering with the newest developments in industrial 3D printing. The current maturation of very large-format steel AM methods – with construct volumes exceeding 1.5 m in all dimensions – has made it doable to straight produce advanced, high-thrust engine parts at full scale. This breakthrough permits radically lowered half counts, generally right down to a single element, and eliminates the necessity for intricate multi-part assemblies, easing precision necessities and minimizing post-machining operations.
The corporate beforehand demonstrated this precept with its 5 kN aerospike engine, manufactured as a single monolithic piece of copper. The brand new reference designs push this strategy dramatically additional. Elements such because the 600 mm-diameter injector head of the XRB-2E6 and its sea-level nozzle, requiring a construct top of roughly 1.6 m, exemplify the size and complexity now achievable.
“The toughest problem stays translating a computational mannequin into actual, testable {hardware},” mentioned Lin Kayser, Co-founder of LEAP 71. “Particularly in turbomachinery, the place sealing, materials fatigue, and transient circumstances throughout startup and shutdown are crucial. These aren’t simply design issues – they demand sensible testing, iteration, and shut collaboration with manufacturing companions.”
This system follows a phased, multi-year strategy. Preliminary testing will give attention to less complicated configurations, comparable to gasoline generator cycles, establishing a strong basis earlier than scaling to extra superior methods.
LEAP 71 is concentrating on the primary take a look at marketing campaign of the XRA-2E5 aerospike engine inside 18 months, with the XRB-2E6 bell-nozzle engine, based mostly on a full-flow staged combustion cycle, deliberate for readiness by 2029.
“This can be a lengthy journey, however the velocity at which we will progress with computational engineering and trendy manufacturing instruments is encouraging,” mentioned Lissner. “We imagine this strategy has the potential to alter how propulsion methods are engineered and constructed.”
LEAP 71 is actively collaborating with AM companions to qualify manufacturing processes for full-scale {hardware}. In parallel, the corporate is working with clients to translate the DNA of its reference designs into flight-ready propulsion methods for orbital missions.
