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Elementum 3D and RPM Innovations, Inc., Successfully Collaborate with NASA to Advance Rocket Engine Design and Performance

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Elementum 3D, collaborating with RPM Innovations, Inc. as part of NASA’s RAMFIRE (Reactive Additive Manufacturing for the Fourth Industrial Revolution) project, designed, printed, and successfully tested a new additively manufactured rocket nozzle made from the company’s A6061-RAM2 aluminum powder. This breakthrough advances ongoing efforts to exceed current rocket performance and efficiency.

ERIE, Colo., July 25, 2024 /PRNewswire-PRWeb/ — Elementum 3D, a leading developer and supplier of metal additive manufacturing (AM) advanced materials, print parameters, and services, is pleased to share that, collaborating with RPM Innovations, Inc. as part of NASA’s RAMFIRE (Reactive Additive Manufacturing for the Fourth Industrial Revolution) project, designed, printed, and successfully tested a new additively manufactured rocket nozzle made from the company’s A6061-RAM2 aluminum powder. This breakthrough advances ongoing efforts to exceed current rocket performance and efficiency.

This breakthrough supports efforts to make large-scale nozzles, including aerospikes, available to industry. This successful project positive result allows aerospace/space engineers to see the nozzle as proof-of-concept that informs new component designs.

In October 2023, at the Marshall Space Flight Center, NASA performed what some thought was impossible: a successful hot-fire test of an additively manufactured aluminum rocket nozzle. The NASA-funded Reactive Additive Manufacturing for the Fourth Industrial Revolution (RAMFIRE) project’s goal was to transition rocket engine technology to a laser powder-directed energy deposition (LP-DED) process to enable large-scale production. The prior approach used lightweight, additively manufactured aluminum alloys printed with a laser-powder bed fusion (L-PBF) process capable of experiencing huge temperature gradients up to 6000 °F.

This breakthrough supports efforts to make large-scale nozzles, including aerospikes, available to industry. The RAMFIRE project printed a large-scale LP-DED aerospike demonstration nozzle with integral channels made of Elementum 3D’s A6061-RAM2. This successful project positive result allows aerospace/space engineers to see the nozzle as proof-of-concept that informs new component designs.

For nearly seven decades, rocket engineers have sought an alternate design to the standard bell-nozzle rocket engine. The aerospike design breaks free from the traditional design, which is efficient at only one point in the rocket’s trajectory.

Why is this innovative nozzle a sought-after option, especially since the bell nozzle is a proven design with adequate capabilities throughout the history of human spaceflight?

The aerospike’s inside-out rocket nozzle plume travels externally, rather than exiting from within a traditional bell-shaped nozzle. The main advantage is that, as the rocket climbs, atmospheric and airstream pressure keep the plume at optimum conditions along the entire trajectory. This allows highly efficient engine performance, including better performance over a range of pressures and altitudes, delivering higher payloads while decreasing overall rocket weight.

If rocket launches are more efficient using the aerospike nozzle design, why has it never been seriously tested on the launchpad?

The lack of actual flight test data has precluded use of these nozzles in current as well as next generation space launch vehicles.

Moreover, the aerospike nozzle configuration presents unique design and fabrication challenges. This and other factors have meant limited test opportunities and a dearth of actual flight test data, precluding use of the aerospike design on current and next generation launch vehicles.

Additive manufacturing has changed perspectives about the ability to test and implement the aerospike design in a cost-effective manner. NASA recently validated data from hot-fire tests on their 3D printed Rotating Detonation Rocket Engine (RDRE), which is not a traditional combustion engine, and reported that recent advancements in 3D printing can overcome some of the engine’s design challenges—specifically, how to manage its temperature. The ability to print the aerospike demonstration nozzle with a qualified high-strength, lightweight aluminum alloy is a significant step toward developing a larger version.

NASA commissioned Elementum 3D to work closely with their RAMFIRE project engineers and scientists and RPM Innovations, Inc., to develop and print a 36″-diameter aluminum aerospike rocket demonstration nozzle out of Elementum 3D’s A6061-RAM2 material. RPM Innovations performed the build with its large-format LP-DED process. DED uses a focused energy source to create 3D printed parts with powder or wire feedstock. With DED, metal deposition and fusion occur simultaneously. A nozzle deposits material into the focused beam of a high-power laser under tightly controlled atmospheric conditions. The feedstock melts and deposits as the tool path progresses.

REM Surface Engineering supported the RAMFIRE project’s post-production with its Extreme ISF Process. They uniformly removed ~400 µm of surface material from the aerospike nozzle surface, which reduced surface roughness/waviness and hot-wall thickness. The benefits of improving the hot wall surface texture include extending the nozzle’s fatigue life and creating a more uniform surface for heat transfer/heat pickup properties. The wall thickness reduction can also bring DED parts into final geometric tolerances. While not performed on this unit, internal channel finishing for rocket nozzles and similar components can reduce particle shedding and pressure drop caused by as-printed roughness.

Why has it taken almost 70 years to successfully produce a lightweight, high-strength aluminum rocket engine?

For one thing, the design requires conformal cooling channels to flow cryogenic propellants that keep the nozzle well below the material’s melting temperature. Internal channels are an additive manufacturing specialty and are far too complex to create with traditional machining processes.

Second, metal additive manufacturing via laser melting processes only became industrialized in the past few decades as computer, automation, and laser technology grew more sophisticated and affordable.

Finally, the ability to additively manufacture aerospace-grade aluminum has only become possible in the past decade. Since 2014, Elementum 3D has gained extensive knowledge and experience developing “impossible-to-print” high-strength aluminum feedstock powders with its patented RAM (Reactive Additive Manufacturing) technology.

Standard aluminum alloys are highly prone to a type of cracking called hot tearing under the rapid heating and cooling conditions inherent to laser welding processes. Industry considers popular wrought aluminum alloys, including AA6061, un-weldable for this reason. Elementum 3D’s RAM chemistry controls the solidification process, producing crack-free, fine-grained microstructures and printed material with strength equal–and in some cases superior–to wrought aluminum.

Will the combination of A6061-RAM2’s optimized thermal and mechanical properties and the design freedom of additive manufacturing be the path to designing and manufacturing new, innovative rocket engines that rival the efficiency of an aerospike rocket engine?

Only time and further research can answer that question. The research data acquired from optimizing A6061-RAM2 aluminum alloy for large blown-powder DED improves engineers’ confidence in the ability to improve rocket efficiency to meet or exceed the aerospike’s performance.

About Elementum 3D, Inc.

Elementum 3D specializes in materials and process development and creating advanced metal alloys and metal ceramic composites. Elementum 3D developed and patented its reactive additive manufacturing (RAM) materials technology, enabling high-performance materials printing which has not been previously possible. The company has several novel feedstock powders with printing parameters available for purchase, and it excels in developing custom materials tailored for specific applications. Elementum3D provides the materials freedom to help companies around the world in their quest to increase product strength, durability, and performance, while reducing weight and cost. Find and follow Elementum 3D on Facebook, Twitter, LinkedIn, and YouTube.

Media Contact

Patrick Callard, Elementum 3D, 1 720-545-9016 37, patrick@elementum3D.com, www.elementum3D.com 

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Global Security & Technology Summit Unveils Month-Long Program of Activities Ahead of December Event

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RIYADH, Saudi Arabia, Oct. 24, 2026 /PRNewswire/ — The Organizing Committee of the Global Security & Technology Summit (GSTS) held an introductory session today at the Ministry of Interior’s headquarters in Riyadh, bringing together representatives from the government, private, and nonprofit sectors to introduce the program of activities leading up to the summit. The upcoming summit will be held in Riyadh under the patronage of HRH Prince Mohammed bin Salman bin Abdulaziz Al Saud, Crown Prince and Prime Minister, under the supervision of HRH Prince Abdulaziz bin Saud bin Naif bin Abdulaziz Al Saud, Minister of Interior, and organized by the Ministry of Interior in cooperation with Tuwaiq Academy.

During the session, the Organizing Committee presented the comprehensive GSTS program, comprising three key components: GSTS Month, running from November 1 to 30, 2026; the Global Security & Innovation Fair (SAIF), taking place from November 24 to 26, 2026; and the main Summit, scheduled for December 18 to 20, 2026, in Riyadh. Together, these events form an integrated program designed to advance security and technology innovation, strengthen national capabilities, and foster international cooperation.

GSTS Month will feature working groups, boot camps, training programs, knowledge-sharing sessions, and technical workshops across Saudi Arabia’s 13 administrative regions, delivered both in person and remotely in collaboration with specialized entities. The month-long program aims to develop national capabilities, identify emerging talent, enrich knowledge-sharing opportunities, and equip professionals with the knowledge and skills needed to develop innovative solutions to future security and technology challenges.

The main Summit will bring together global leaders, decision-makers, experts, and innovators to explore the future of security and technology, promote the integration of advanced technologies within the security sector, strengthen national capabilities, support innovation, and foster international cooperation, further positioning the Kingdom as a global hub for security and technology.

Showcasing the latest technological breakthroughs and security solutions, the summit will bring together government entities, private sector organizations, academic institutions, and research centers to facilitate knowledge exchange and collaboration across key fields, including cybersecurity, artificial intelligence (AI), the Internet of Things (IoT), smart security solutions, emerging technologies, and crisis management. The program will also feature main sessions, specialized discussions, and interactive exhibitions. Registration is available at gsts.sa.

Advisor to HRH the Minister of Interior and Chairman of the GSTS Organizing Committee, Ahmed Altowayan, stated that the summit builds on Saudi Arabia’s efforts to establish an advanced security and technology ecosystem focused on knowledge and innovation, keeping pace with rapid developments and future challenges.

Mr. Altowayan noted that the summit is a global platform for strengthening cooperation and exchanging expertise, anticipating future developments in security and technology, and developing strategic partnerships and innovative solutions that enhance the efficiency and readiness of security systems.

Vice Chairman of the GSTS Organizing Committee, Eng. Abdulaziz Alhammadi, said that the summit will offer a range of integrated programs and activities focused on enhancing national skills, encouraging innovation, and supporting international cooperation.

He added that GSTS Month will help build national capabilities, discover talent, and develop skills, with SAIF providing a platform for innovators and researchers from around the world to showcase leading technological solutions, while the main Summit will bring together leaders and experts to discuss the future of security and technology and explore new strategic partnership opportunities.

SAIF will take place at the Riyadh International Convention & Exhibition Center, bringing together innovators, researchers, technology talents, and industry experts from around the world to showcase promising innovations and projects across 14 fields of technology and innovation. The fair will provide opportunities to engage with project owners, including students, graduates, and entrepreneurs, and explore the different stages of innovation development through interactive zones, panel discussions on emerging security and innovation trends, and knowledge-sharing workshops led by specialists. Visitor registration is open to participants from within and outside the Kingdom through saifair.sa.

The introductory session also featured contributions from representatives of government, private, and nonprofit sector entities, alongside members of the media. Discussions focused on developing national capabilities in security and technology, strengthening students’ technical expertise, translating scientific research into practical solutions, and supporting Saudi companies in developing security and technology solutions and advancing digital transformation.

Organized by the Ministry of Interior in cooperation with Tuwaiq Academy, GSTS is produced by Tahaluf, with the Ministry of Education serving as Strategic Scientific Partner, Tahakom as Founding Partner, and Elm as Principal Partner.

Registration for participants from within and outside the Kingdom is available at gsts.sa.

Click here to view the media kit. 

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Axon Announces Body 5: Next-Generation Camera Built for the AI Era

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Axon Body 5 delivers 25x the AI processing power of earlier-generation cameras, with upgraded connectivity, audio and battery life to support real-time situational awareness in the field

SCOTTSDALE, Ariz., Oct. 24, 2026 /PRNewswire/ — Axon (Nasdaq: AXON), the global leader in public safety technology, today announced Axon Body 5, its newest body-worn camera designed to bring more powerful intelligence, connectivity and real-time support directly to officers in the field.

For years, Axon body cameras have helped agencies capture critical evidence and create greater transparency. Body 5 is built to help officers during the call, with information, assistance and backup on the spot.

“Officers shouldn’t have to choose between getting information and watching the scene. With Axon Body 5, they don’t,” said Rick Smith, Axon Founder and CEO. “They capture a license or document with the camera, keep their hands free and eyes up, and get information faster than writing it down and calling it in by radio. An officer fully engaged with the person in front of them, not down at a notepad, is a safer officer and a better-served community.”

Axon Body 5: Built for the AI Era

Built from the ground up for the AI era, Axon Body 5 delivers 25x the AI processing power than earlier generation Axon body cameras, alongside advancements in connectivity, audio, video and battery life. Together, these upgrades give the camera the physical power to run smarter AI features — both today and as new AI tools are developed in the future — while also making it more dependable for officers to use every day. 

For the first time, Axon is also introducing two versions of its latest flagship camera: Axon Body 5 and Axon Body 5 Pro.

Both models feature several key advancements, including:

25x more processing power for AI: A powerful new computing architecture creates the capacity to support current and future AI features directly on the body camera.Enhanced video: Improved video captures clearer evidence across challenging environments, including better low-light performance.Improved connectivity: Seamless connectivity in urban and remote environments – and more precise location capability – helps officers, cameras and remote support teams stay connected when timely information matters most.Longer battery life: 20% more battery life than the previous generation helps keep the camera ready and connected throughout an officer’s shift.

The Axon Body 5 Pro will continue to gain new AI capabilities as they become available, growing along with the AI Era Plan. Additionally, new hardware features include:

A near-focus camera: An additional dedicated camera lens lets officers scan driver’s licenses to check status and search for wants or warrants in seconds, without returning to the patrol vehicle, with relevant information sent to Axon Fusus to support real-time operations.Front-facing speakers: Four additional speakers project even more powerful audio toward the person an officer is speaking with, helping real-time translations from Axon Assistant carry more clearly over heavy traffic or crowd noise. Additional memory: Extra space lets the camera run several AI tools at once, helping officers stay better informed and work faster.

Bringing More of Axon’s AI Era Into the Field

Axon Body 5 helps officers get more out of the Axon AI Era Plan by bringing smart tools right to the scene. Axon’s portfolio already supports public safety professionals across a growing range of tasks. For example, Draft One helps officers turn body-camera audio into high-quality report drafts and Axon Assistant provides voice-based information access and real-time translation.

Increasingly, Axon is also bringing AI into real-time operations.

Axon Guardian is a new category of AI features within the AI Era Plan that was specifically created to work with an officer’s field-based devices – starting with body cameras and in-car cameras – to improve safety. Guardian is designed to flag potential risks as situations unfold and create alerts when additional attention may be needed. Two of the first features include:

Escalation Detection: When an Axon Body 4 or Axon Body 5 camera is activated and recording, Guardian has the ability to detect potential conflicts in real time and create an alert in Axon Fusus. A human reviews the livestream and decides if additional support or action is needed.Approach Alert: When active on Axon Fleet 3, Guardian can detect if the door of a stopped vehicle opens and alert the officer through the in-car display and their body-worn camera.

Combined, Axon Body 5 and the expanding AI Era portfolio demonstrate the importance of AI as a critical resource to assist public safety professionals before, during and after an incident — reducing administrative burden, improving situational awareness and helping protect more lives.

Innovating Responsibly

Axon’s Responsible Innovation framework guides the development of all of its products. Designed with this in mind, Axon Body 5 and Guardian prioritize human oversight and maintain agency control over data. As a key part of the responsible innovation process, Axon’s independent Ethics and Equity Advisory Council was created to help responsibly develop and deploy new technologies with transparency, while aligning with community expectations.

General availability dates for Axon Body 5 and Axon Guardian will be announced soon. Product features and capabilities vary by configuration. For more information on Axon’s current products and services: Axon Product Catalog – Axon.com.

About Axon
Axon (Nasdaq: AXON) is the global leader in public safety technology supporting state, local, federal and international public safety agencies with technology designed to Protect Life. Complementing its mission, Axon’s growing Enterprise market focuses on protecting critical infrastructure and frontline workers across multiple industries including corporate security, hospitality, retail and healthcare. Founder-led since 1993, Axon builds products with transparency and responsibility. From TASER energy devices to today’s connected network of hardware – including cameras, drones, and robotics – cloud software, sensors, and AI-tools, the Axon ecosystem helps seamlessly protect people and places when it matters most. To ensure these technologies align with community expectations, Axon’s independent Ethics & Equity Advisory Council guides the ethical, inclusive, and accountable design of its products and services. Learn more about the EEAC and Axon’s Responsible Innovation framework at Axon Responsibility. 

Non-Axon trademarks are the property of their respective owners. Axon, TASER and the Delta Logo are trademarks of Axon Enterprise, Inc., some of which are registered in the US and other countries. For more information, visit www.axon.com/legal. All rights reserved.

Please visit https://investor.axon.com and https://www.axon.com/newsroom for more information.

Media Contact:
Kate MacKinnon
Vice President, Communications
press@axon.com

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In HelloNation, Custom Fabrication Expert Mark Coyle Explains a Common Mistake in Custom Aluminum Design

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The article explains why smart geometry, not thicker walls, creates stronger, more efficient aluminum components.

ROCHESTER, N.Y., Oct. 24, 2026 /PRNewswire/ — What early design choice causes many custom aluminum projects to become heavier, costlier, or harder to manufacture? That question is addressed in a HelloNation article featuring insights from Custom Fabrication Expert Mark Coyle of American Custom Metals, Inc. in Rochester, New York, that outlines how misunderstanding aluminum behavior leads designers to rely on thick walls instead of stronger geometry.

The article begins by explaining that many people assume thicker walls automatically make aluminum parts stronger. It notes that aluminum does not respond to wall thickness the way steel does. Instead, its performance is shaped by how the metal flows through the extrusion die. The article states that custom aluminum design is more effective when profiles use ribs, chambers, and flanges to create stiffness without adding unnecessary weight. This guidance helps readers understand why adding material often increases cost without improving strength.

The article also highlights that thicker walls change how aluminum moves during extrusion. When heavy areas fill more slowly, the metal cools unevenly and can develop stress that only appears later. The HelloNation piece explains that well-balanced geometry keeps extrusion smooth and predictable. This consistency makes it easier to maintain dimensional accuracy across long production runs. By focusing on geometry, custom aluminum design avoids the problems that come with slow extrusion speeds and uneven cooling.

Another insight in the article centers on how ribs and internal supports influence stability. It describes how a thin wall supported by a properly placed rib often performs better than a thick wall with no reinforcement. This happens because the rib helps distribute load, improve stiffness, and guide the aluminum as it cools. The article explains that this structural approach makes custom aluminum design more efficient and gives designers more control over how the final part behaves under pressure.

The article also shows why early collaboration between designer and fabricator prevents costly changes. It states that a fabricator familiar with extrusion can catch potential issues before a die is built. Small adjustments to corners or transitions can remove weak points or improve metal flow. The article notes that this teamwork keeps the design aligned with real-world production. By working together early, both sides reduce the risk of redesigning the die after the first test run.

Machining is another area where the article explains how wall thickness affects performance. Features such as deep pockets or sharp internal angles may require slow feed rates or special tooling. When walls are thicker than needed, those areas can become difficult to machine cleanly. The article states that thoughtful custom aluminum design makes machining more predictable. Small changes, such as adding radiused edges or sizing features to match standard tools, help shorten cycle times and prevent tool wear.

Thermal behavior receives detailed attention as well. The article explains that aluminum retains heat differently depending on the mass of each section. Thicker walls hold heat longer, which increases the chance of distortion during extrusion, machining, or finishing. When a design uses geometry to create strength, the material cools more evenly. This reduces warping and helps long profiles stay aligned. The article notes that stable cooling is important for components that require a precise fit and consistent shape throughout an entire production run.

Cost is also a key topic in the article. It states that heavier profiles increase material use, extrusion time, and tooling needs. A custom aluminum design that relies on geometry instead of mass lowers material consumption and keeps the fabrication process efficient. The article explains that lighter parts are easier to handle, ship, and assemble. This saves money across multiple stages of production and supports long-term manufacturing efficiency.

The article also notes that smart custom aluminum design creates profiles that behave predictably during extrusion and machining. Smooth transitions, balanced wall dimensions, and structural features help reduce the chance of distortion or dimensional drift. These elements also lower scrap rates and support reliable performance. By using geometry instead of excess material, designers build parts that maintain strength without compromising manufacturability.

As the article concludes, it emphasizes that avoiding thick walls is one of the best ways to improve performance and lower cost. It states that the most dependable custom aluminum components come from designs that use structural features to strengthen the profile. When designers understand how aluminum behaves at each stage of extrusion and machining, they create parts that are strong, efficient, and consistent from batch to batch. This approach turns custom aluminum design into a predictable process rather than a series of uncertain adjustments.

A Common Mistake in Custom Aluminum Design features insights from Mark Coyle, Custom Fabrication Expert of Rochester, NY, in HelloNation.

About HelloNation
HelloNation is America’s Good News Network, a premier media platform built on the idea that good news travels faster when real people tell real stories. Through its community-focused publications and innovative “edvertising” approach, HelloNation delivers content that informs, inspires, and spotlights the leaders making a meaningful impact in their communities.

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