Latest news with #Leap71
Yahoo
5 days ago
- Science
- Yahoo
The Elusive Aerospike Engine Is Finally Moving From Theory to Reality
Here's what you'll learn when you read this story: The aerospike engine—which uses air pressure to shape the downward force needed to launch a spacecraft—has been on the cusp of entering mainstream rocketry for decades. Now, a new company called Leap 71 is moving fast, designing a new aerospike engine and 3D printing it for testing all within a few weeks. The successful test this past December paved the way for the company's adoption of a reference design called the Noyron XRA-2E5, which could be tested no later than the end of 2026. For 65 years of human spaceflight, rockets ferrying astronauts to the stars have all had bell-shaped nozzles specifically designed to produce enough thrust to lift massive payloads off the launchpad. But this decades-old design comes with limitations. The biggest one is that bell nozzles only work optimally at certain atmospheric pressures, which is one reason why most rockets actually contain many stages during a mission. If you could improve this inefficiency, rockets could just have one single stage that they use for the entire mission. That would save on payload weight and, of course, money. So, for decades, scientists have wondered whether other geometric designs—ones that could effectively adjust to atmospheric pressure during flight—could one day replace bell-shaped nozzles. The leading contender is an idea known as the aerospike, which relies on atmospheric pressure itself to create the outside wall of a virtual bell. The idea is that as atmospheric pressure changes, the bell itself would change as well. The idea isn't new, as this rocket engine—designed in both toroidal and linear configurations—has been on the precipice of the mainstream ever since NASA strapped one to an SR-71 in the 90s. However, the engine has never proven itself to be adequate replacement for traditional rocket bells. But times have changed, and in 2024, the aerospike had one of its best years in recent memory. In late October, the German aerospace company Polaris Spaceplanes successfully demonstrated a linear aerospike (LAS) engine mid-flight. Now, the company hopes to launch a successor, called the Nova, in 2025. But it was actually a late entry from the Dubai-based computational engineering company Leap 71 that gave a glimpse of what the future research into aerospikes—and aerospace propulsion more broadly—might look like. On December 18, 2024, the company test fired its oxygen-and-kerosene-burning toroidal aerospike rocket for 11 seconds, recording a 1,110 pounds of thrust. And while that's cool in and of itself, it's not as impressive as how it was made. Leap 71 used an in-house AI computation engineering model known as Noyron to design the rocket and then used a 3D-printing technique known as 'Laser Powder Bed Fusion' to create an engine built from an aerospace copper alloy. Building a new rocket engine usually takes several years (at least), but Leap 71 claims that their aerospike engine took only a matter of weeks to design, manufacture, and test. The company even addressed one of the aerospike's biggest design challenges—how to cool the spike itself. 'We were able to extend Noyron's physics to deal with the unique complexity of this engine type,' Leap 71 CEO Josefine Lissner said in a press statement. 'The spike is cooled by intricate cooling channels flooded by cryogenic oxygen, whereas the outside of the chamber is cooled by the kerosene fuel.' In April 2025, the company announced that they're moving forward with an aerospike reference design called the Noyron XRA-2E5, and it hopes to perform first tests on the design by the end of 2026. Aerospike engines have long been waiting for a chance to prove their usefulness, and thanks to AI computational tools and rapid prototyping via 3D printing, that chance may come much sooner than anyone expected. You Might Also Like The Do's and Don'ts of Using Painter's Tape The Best Portable BBQ Grills for Cooking Anywhere Can a Smart Watch Prolong Your Life?
The National
26-06-2025
- Business
- The National
Plan for UAE-built rockets primed to boost standing in global space race
A major private sector partnership aimed at developing UAE-built reusable rockets is set to propel the country's soaring ambitions in the global space race. Aspire Space, a European aerospace firm, is relocating its headquarters to the Emirates and has joined forces with Dubai-based Leap 71 to build the two-stage rocket system. The vehicle is designed to carry up to 15 tonnes to low-Earth orbit and is scheduled for its debut launch in 2030. The agreement could help the UAE establish sovereign access to space, a capability that only a few nations, such as the US, Russia, Europe and China, currently has. 'We are planning the first launch in 2030, and I would say that it's a very ambitious timeline. The very important thing for us, of course, is to have the partnership with the propulsion systems experts,' Stan Rudenko, chief executive of Aspire, told The National. Aspire's rocket will be powered by Methalox engines, using liquid methane and liquid oxygen, designed and developed by Leap 71 using artificial intelligence. The propulsion systems will be built entirely in the UAE. A launch site for these rockets has not yet been confirmed, but Lin Kayser, co-founder of Leap 71, said Oman was a promising option. Region's growing space sector Oman is developing the Etlaq spaceport – a 10-hour drive from Dubai – and has been carrying out test launches from the site, with commercial operations set for later this decade. 'Oman has a fantastic place for launching rockets,' said Mr Kayser. 'So, we're saying let's build the rockets and engines here … and then maybe the right place to launch is over there.' Sovereign access to space The UAE has made significant progress in its space ambitions, from sending astronauts to the International Space Station to launching a probe to Mars and developing lunar rovers. But one key capability still missing is the ability to launch its own missions using domestically built rockets. 'Any region that wants to participate in the space economy fundamentally needs sovereign access to space, because otherwise you're always relying on someone else,' said Mr Kayser. 'The other person that you're relying on will set the prices and can give you access or not.' He pointed to the difficulties faced by global tech giants when relying on foreign launch providers, including how Amazon's Jeff Bezos was unable to launch his Kuiper satellites because of limited rocket availability. 'And I think Elon Musk doesn't really want to fly this stuff, so it's tough for him to launch a competing constellation,' said Mr Kayser. Rockets and engines built in the Emirates Leap 71 is now designing and building the propulsion systems for Aspire's new reusable rocket, based on its XRB-2E6 engine that produces 2,000 kilonewtons of thrust. The work is being done using Noyron, an artificial intelligence model involving an algorithm that can generate rocket engines, including software codes that command the engine how much thrust and propellant it needs to have. It then powers the engine without any human intervention. 'Our proposition, as Leap 71, is if we build propulsion systems, then launcher companies will come here,' Mr Kayser said. 'Because you cannot buy propulsion systems on the free market … outside the United States you cannot really do that. 'Boeing and Airbus builds airframes, but GE and Rolls-Royce build the engines. 'And that's basically what we're proposing for rocketry … it makes the same amount of sense it does for airplanes.' Leap 71 has already validated its technology using smaller engines and is now shifting to much larger propulsion systems required for orbital rockets. But developing and testing large rocket engines requires specialised centres. Transporting them across borders is impractical and often restricted due to export controls. 'You can test them somewhere else, but if you want to build larger engines, you have to build test sites here in the UAE,' Mr Kayser said. 'You have to produce them here … it's not like you can just ship them around the world.' He said this approach ensures the entire rocket development pipeline, from design to testing and manufacturing, remains in the UAE. From legacy to next generation Aspire was founded in 2023 in Luxembourg by engineers who have spent decades developing major launch systems. Many of them worked on the Soviet-era Zenit and Soyuz programmes, as well as the multinational Sea Launch initiative. That team is now expanding, with Aspire planning to hire 20 new employees, including rocket scientists, in the UAE. The company also has plans to develop a reusable capsule that would send cargo, and eventually humans, to space stations.
The National
15-05-2025
- Business
- The National
Success of Elon Musk's Starship ‘more important than ever' in light of proposed budget cuts to Nasa
SpaceX's Starship rocket is poised to become one of the most critical assets in US space ambitions, experts have said. The comments come as the White House's proposed budget cuts cast doubt on Nasa projects such as the SLS rocket and Orion capsule, both technologies which would be used to take astronauts to the Moon. Space industry experts told The National that Starship could be the foundation of a new era in exploration, one that relies on powerful rockets, called heavy-lift vehicles, capable of carrying megatons of cargo and astronauts to the Moon and Mars. The Starship rocket, however, is still under development, with test flights being carried out since 2023 from Boca Chica, Texas. The next test flight is potentially scheduled for May 21. 'With the future of Nasa's SLS and Orion uncertain due to rising costs and limited reusability, Starship is increasingly emerging as the de facto backbone of US launch infrastructure,' said Lin Kayser, co-founder of Dubai company Leap 71, which develops artificial-intelligence models to generate rocket engines. 'SpaceX is already the primary launch provider for the US government and with Starship it becomes a near-monopoly at the high end of launch capability. That level of centralisation raises strategic concerns but it also highlights how far ahead SpaceX has pulled.' Nasa had developed the SLS rocket for its Moon programme Artemis but each launch would have reportedly cost $4 billion and the entire programme is behind schedule. Billionaire Elon Musk, founder of SpaceX, has said Starship projects would be at a fraction of cost. SpaceX has also made rapid progress through an iterative testing approach, which has helped speed up development compared to traditional government programmes. The company, however, still faces technical challenges before commercial operations of the powerful rocket can begin. Starship's eighth test flight in March ended with the spacecraft destroyed, though the booster was recovered successfully. The test next week will be crucial in proving the vehicle's ability to operate reliably and safely. 'With Nasa's budget cuts looming and SLS and Orion on the chopping block, Starship has become increasingly important,' said Sahith Madara, an aerospace engineer and founder of Paris advisory firm Bumi & Space. 'It's ironic to see that what was once a 'back-up' is now carrying the entire weight of the US deep-space ambitions.' The shift comes as the White House proposes slashing Nasa's budget by 24 per cent, from $24.8 billion to $18.8 billion, in 2026. The cut could affect major science missions, the International Space Station and planned Moon landings. It could also reshape how the US approaches space exploration, with the private sector playing a more dominant role. Mr Kayser said Starship is also important in enabling a range of new commercial applications in orbit. 'Starship is the enabler for an entire class of orbital infrastructure. Starlink 2.0 cannot launch without it. The upcoming generation of direct-to-device internet, including global smartphone connectivity and real-time voice calls from orbit, will hinge on this vehicle,' said Mr Kayser. He said beyond communications, companies are exploring the use of space for data centres and advanced manufacturing, thanks to Starship's scale and payload capacity. 'AI data centre infrastructure is now migrating to space to take advantage of unlimited solar energy and passive radiative cooling," he said. 'It's about who will dominate the next trillion-dollar layer of the global economy. Anyone who wants to compete in that race needs to be building right now.' Dave Barnhart, chief executive of California-based space infrastructure firm Arkisys, said the proposed cuts could push industry players to step up faster to fill the gaps. 'The ability for Nasa to continue its fundamental mission of science growth in space requires a variety of transport, platform and ground logistics,' he said. 'Starship is important to replace heavy lift loss of SLS, as are smaller launch vehicles to support higher cadence. "Near-term loss of Nasa key infrastructure elements, I believe, will incentivise and tap into fast response by industry to step up, support Nasa goals and accelerate their science goals.' While SpaceX leads the current heavy-lift race, it is not the only private company in the game. Blue Origin, founded by Jeff Bezos, has also developed its own heavy-lift rocket, called New Glenn. The vehicle was launched successfully for the first time in January. The Federal Aviation Administration recently approved up to 25 Starship launches a year, up from only five previously, giving SpaceX a clearer path to scaling up operations. Mr Musk is set to arrive in the UAE on Thursday, as part of a Gulf visit alongside US President Donald Trump.
Fast Company
15-05-2025
- Business
- Fast Company
AI is printing the rocket engine that could beat SpaceX at its own game
SpaceX owns 98% of global rocket launches, a monopoly with virtually no competition. Only China is competing with Elon Musk at this point in number of launches and, while the country is getting closer to mass-producing reusable rockets, it appears far from making that happen. The world needs to scramble. We can't let a single company dominate the future of humanity—and much less one that is owned by Musk. 'If you copy SpaceX, it'll take you 10 years to get where they are today,' Lin Kayser, cofounder of Dubai-based engineering AI firm Leap 71, tells me in a video interview. 'But in 10 years, SpaceX won't be where they are today. The game will be over.' Startups and nations need to catch up to Musk, but that means solving a brutal equation: designing engines with comparable thrust (measured in kilonewtons, or kN) and efficiency, but without the decade-long development cycles. And to beat SpaceX, you also need to be able to mass-produce the rockets. This is now more important than ever because the stakes are even higher than just five years ago. Satellite constellations like Starlink, which may soon enable direct-to-phone internet, threaten to sideline telecom operators and centralize control of earth's critical communication infrastructure on top of controlling the space economy. 'Every region needs sovereign launch capability,' Kayser contends. 'Otherwise, you'll pay 10 times what SpaceX pays to access space—if they let you.' His company may have a solution to fix that conundrum. Leap 71 developed artificial intelligence called Noyron that, so far, has successfully designed two rocket engines. Kayser believes that his company, legacy rocket makers, and startups will be able to leverage this synthetic rocket engineer to create a cheaper match to the SpaceX Raptor—and beat Musk at his own game. The 10-foot-high Raptor—which powers the Starship—is arguably the most advanced Western rocket engine in production. Its latest iteration produces 280 tonnes of thrust at sea level, surpassing competing engines like Blue Origin's BE-4. It uses methalox, an efficient fuel that can be manufactured in places like Mars, which makes it key for deep-space exploration. But the Raptor's importance lies in the fact that it is the first operational full-flow staged combustion (FFSC) engine in history. This means that it optimizes efficiency and thrust while minimizing thermal stress, so you can reuse it many times, the key for cheap, sustainable space exploration. Only two other FFSC engines have been tested, but they've never flown. Leap 71 now wants to achieve the same spaces but better, with fewer 3D-printed pieces, which will make it less expensive than Musk's engine. Computational blueprint Leap 71 describes its Noyron computational model as an 'engineer brain in a box.' Unlike generative AI tools that require human oversight because they are just guessing what could work, Noyron encodes physics, material science, and manufacturing rules to autonomously design rocket engines. It generates not just shapes but also functional hardware ready for 3D printing. 'Traditional parametric CAD is geometry-driven. Ours is physics-driven,' Kayser explains. 'Calling it parametric CAD would be like saying ChatGPT is autocomplete.' The system's first breakthrough came in 2024 with a 5 kN rocket engine. The compact, high-efficiency rocket was fully designed by AI and 3D printed in one go as a single-piece copper engine with intricate internal cooling channels. During trials in an old World War II bunker in the U.K., the engine fired flawlessly, validating Noyron's ability to predict thermal stresses and fluid dynamics. Then, in January 2025, Leap 71 really pushed the envelope by designing one of the most challenging and elusive rocket engines in the aerospace industry: a cryogenic aerospike thruster, an engine capable of working at every altitude to eliminate the need for multiple rocket stages, minimizing elements and costs in the process. Now the company wants to scale up this approach to engines 400 times larger. The new road map includes two reference designs: the 200 kN XRA-2E5 aerospike and the 2,000 kN XRB-2E6 bell-nozzle engine, equivalent to SpaceX's Raptor. The first, he says, is slated for testing within 18 months of April 2025 (placing it around late 2026). The second is targeted for readiness by 2029. For rocket engine development—with design and testing cycles measured in decades—this is incredibly ambitious. But the timeline is achievable because of how Noyron works, Kayser says. Instead of manually iterating prototypes, Noyron treats all engines as variations of a unified 'DNA.' And instead of having to be programmed, its edge lies in its ability to absorb decades of engineering knowledge—even from obscure sources. For its new model, Leap 71 has not only incorporated learnings from its past tests (like data on cooling efficiency and material strain), but also vast amounts of new information, including digitized Soviet-era rocket manuals. 'We plug these into Noyron to refine our thermal models,' Kayser says. The AI also learns from every test, creating a feedback loop that collapses design cycles and speeds up the development process. Noyron is not generative AI, but a computational model capable of producing deterministic results that are consistent every time. They are accurate according to the actual physical world and data. It understands. It doesn't just guess. Input the same specs, and it generates identical designs (try that with ChatGPT, Gemini, Midjourney, or Sora). This is critical for aerospace reliability. 'Human engineers can see the rationale behind every decision,' Kayser says. 'It's not a black box.' The challenges While Noyron can design a rocket engine in minutes, proving it works in the physical world is the real test. The company's ambitions collide with a stark reality: Even the most advanced AI cannot shortcut the laws of physics and bureaucracy. Securing test facilities for large engines is another hurdle. While smaller subsystems (like the 28 kN turbopump it wants to test this year) fit on existing stands, the 2,000 kN engine's sheer size demands specialized infrastructure. 'The critical path here is test-stand availability,' says Kayser. Current options are scarce and scattered around the world. Shipping engines abroad triggers export controls and delays—a problem compounded by geopolitical tensions. Moving a small engine from Germany to the U.K. already takes 'two to three weeks,' Kayser tells me. That's why Leap 71 is in talks with governments in Dubai, Singapore, and New Zealand to co-locate manufacturing and testing. Oman's planned spaceport and New Zealand's remote Tāwhaki facility, with its vast sound-dampening landscapes, are leading candidates. 'You can't just put a loud rocket engine next to a city,' Kayser says. The other challenge—the actual production of the engine—has only just become possible, with China's new 3D-printing behemoths capable of producing parts that are 6.56-by-6.56-by-3.60 feet. In fact, this is what led Kayser and his partner, Leap 71 cofounder Josefine Lissner, to believe that making a Raptor-class engine was even possible. Called the EP-M2050 (and manufactured by Eplus3D), this colossal 3D printer uses 36 lasers to turn metallic powders into all the parts needed for next-gen rocket engines, including the nozzles, which will be much taller than your average human. The printers are so new that quality assurance is still a question mark. Surface roughness, inherent to layered metal printing, disrupts fluid dynamics in cooling channels. Rough walls increase friction, altering fuel flow and thermal stability. Post-printing, parts undergo rigorous cleaning to remove residual metal powder, a task that until now has been handled by German firm Solukon because 'any impurities could cause an explosion,' Kayser says. Material uniformity is another gamble. While printers handle alloys like copper-chromium-zirconium, ensuring consistent strength in massive components—especially under the violent vibrations and thermal swings of a firing engine—remains unproven at this scale. The turbopump, which forces fuel into the combustion chamber at extreme pressures, epitomizes this challenge. Leap 71's 28 kN test rig validates principles for larger designs, but scaling amplifies risks. Turbines spin at supersonic speeds, generating centrifugal forces that warp metal. Rapid temperature shifts—like the -297°F cryogenic oxygen flow meeting 5,430°F exhaust—threaten cracks. 'Sealing, material fatigue, and transient conditions during start-up and shutdown are critical,' Kayser explains. 'These are not just design problems—they demand practical testing.' That's why the most unnerving hurdle of rocket development with this method is 'blind testing.' Leap 71's aerospike engine, printed as a single copper block with internal cooling channels, could not be inspected internally before firing. 'We had to test blind,' Kayser says. During trials, imperfect oxygen flow led to higher-than-expected temperatures. Although it all worked, it forced an early shutdown. 'Instead of risking additional runs, we cut the engine in half to analyze it,' Kayser adds. Each failure feeds back into Noyron's models, but iteration consumes time and capital. For now, Leap 71's strategy hinges on incremental validation—testing subsystems like injectors and turbopumps individually—while lobbying governments to fund dedicated test facilities. The road ahead While these are big challenges, they are not insurmountable. The space industry knows it and, according to Kayser, wants a piece of the action. Everyone is looking for a way to leapfrog several years and catch up to—or surpass—Musk. Right now, Leap 71 collaborates with about 15 rocket startups. Kayser can't disclose their names under confidentiality agreements except for the Exploration Co., which is developing a European Moon lander. These partners lack SpaceX's vertical integration but want tailored engines without decade-long R&D. 'The engine is the most expensive and complicated part,' Kayser emphasizes. 'Everyone else just buys them. But there's no supply.' L3Harris—which now owns the legendary rocket engine maker Aerojet Rocketdyne, makers of the Apollo engines—wants to sell them, but it doesn't have anything comparable to the Raptor. Blue Origin makes and sells engines for the United Launch Alliance (ULA), but nobody else. The Russian NPO Energomash once dominated the global rocket engine market, supplying the RD-180 that powered ULA's Atlas V rocket for decades. But RD-180s are now considered relics—and are under sanctions because of the Ukraine war, anyway. '[Current design processes] are actually a problem for many of the micro launcher companies right now,' Kayser says. 'So they have relatively small engines. And if they now want to play in the higher leagues, they basically have to embark on a completely new project, create a completely new rocket.' The main differentiation between sizes is the engine, because the rest of the rocket is scalable. It's harder to scale up the engine because it has completely different specifications and requirements. By using Noyron, Kayser says customers will be able to fine-tune to their own needs and input thrust, fuel type, and size to receive bespoke engine designs for every need. A startup might tweak an aerospike for methane fuel, while another firm could optimize for cost. Some engines will be small and some could be Raptor-class. We will know if it all works in just a couple of years, so we won't have to wait long: Kayser tells me that he and Lissner expect the first hot firing of the 200 kN XRA-2E5 aerospike engine in October 2026. Full-scale testing of the large 2,000 kN Raptor-class engine is tentatively planned to begin in 2028, with qualification for flight readiness stretching into 2029. If Leap 71 can pull it off, it will be phenomenal for humanity. A new process for rocket development will challenge Elon Musk at his own game and democratize the means to reach orbit for every country on the planet. Plus, if it happens, the dream of having Tony Stark's J.A.R.V.I.S.-like AI to aid humans to build the future will be real. Kayser certainly believes in it: 'We're building a world where anyone can engineer complex machines.'
The National
06-05-2025
- Business
- The National
Dubai company builds 3D-printed rocket engines as big as Elon Musk's
An AI engineering company in Dubai is scaling up its 3D-printed rocket engines to match the size of Elon Musk's SpaceX Starship Raptors, which could redefine how next-generation space hardware is built. Leap 71, which uses AI algorithms to design complex propulsion systems, is moving from small test engines to models powerful enough for full-scale orbital launches. With major advances in metal 3D printing, the company says it can now produce engines nearly two metres across, sizes that were previously too large for 3D printers to handle. 'Our customers want to fly to space with our engines, so now we are scaling them massively,' Lin Kayser, co-founder of the company, told The National. Unlike traditional aerospace companies that rely on teams of engineers to manually design rocket components, Leap 71 uses a computer system powered by AI to generate engine designs. The AI model, called Noyron, involves an algorithm that can generate rocket engines, including software codes that command the engine how much thrust and propellant it needs to have. Once the AI generates a design, it can be fed directly into a 3D printer to create the hardware. 'After an initial test last year, we test-fired eight more rocket engines, all of them different and designed by our computational system,' said Mr Kayser. Until now, Leap 71's engines have been relatively small, at about 30cm in diameter, making them useful for spacecraft like lunar landing vehicles. But to move into orbital launches, Mr Kayser said the engines needed to be much bigger. The company is now developing engines that require industrial 3D printers with build volumes close to two metres. Such printers, which use metal powder to build parts layer by layer, have become available only in the past 18 months, driven mostly by rapid progress in China. 'There's a number of 3D-printer manufacturers that can now support these extremely large-build volumes, which is really difficult because it's tonnes of metal powder that go in into these things,' said Mr Kayser. The company's newer designs include meganewton-class engines, those capable of producing thrust in the range of 1,000 to 2,000 kilonewtons, putting them in the same category as some of the world's most powerful rocket engines. But those engines would still have to be test-fired to ensure they work as expected. A key hurdle for Leap 71 is a lack of test stands, specialised sites where rocket engines are fired, in the country. These are essential but difficult to build due to safety, noise and regulatory requirements. Leap 71 hopes to set up its first rocket engine factory in the UAE, where it can take advantage of the country's growing ambitions in space. Sahith Reddy Madara, an aerospace engineer and founder of advisory firm Bumi & Space, told The National that Leap 71's work could be a game-changer. 'What Leap 71 is doing represents a promising step towards redefining how we approach rocket engine development,' he said. 'This method could democratise access to advanced propulsion technologies, lowering barriers for smaller players by reducing the need for large in-house engineering teams and long development cycles. That said, widespread adoption will depend on how these designs perform under real-world conditions and whether they can meet the rigorous reliability standards of spaceflight.' Leap 71's current business model is built around supplying what it calls 'reference engines', which are functional, baseline models that space companies can adapt to their own needs. It hopes to eventually carve out a niche supplying engines that can power everything from small orbital rockets to larger reusable systems. The company's AI-led method can dramatically shorten development times and lower costs, which could be especially appealing to smaller or newer players in the space sector. It already has a partnership with The Exploration Company, a European firm which is developing and manufacturing a reusable space capsule called Nyx. The collaboration would integrate Leap 71's AI-designed engines into future missions.
