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Collaboration between SpaceForest and AGH University: Development of CFRC composite technologies

BySpaceForest
AGH staff examining SF-100 thrusters during a meeting at SpaceForest headquarters.
AGH researchers inspect the SF-100 thrusters at SpaceForest during a collaboration meeting.

Meeting at SpaceForest

On July 9, 2024, a meeting took place at SpaceForest headquarters between the company’s representatives and scientists from the Stanisław Staszic AGH University of Science and Technology in Kraków (AGH). The visit included Dr. hab. Eng. Aneta Frączek-Szczypta, professor at AGH, and Dr. Eng. Maciej Gubernat from the Faculty of Materials Science and Ceramics at AGH. The main topic of discussion was reviewing the ongoing collaboration within the framework of the Lider XIII project, funded by the National Centre for Research and Development. The project, titled “Development of a New Generation of Rocket Engine Nozzles Made of Carbon-Carbon Composite Material” (No. 0108/L-13/2022), aims to develop advanced rocket nozzles made from Carbon Fiber Reinforced Composite (CFRC).

Progress in CFRC nozzle research

During the visit, the participants discussed the research progress and the upcoming tests of the first batch of CFRC nozzles. These advanced nozzles were produced in AGH laboratories and will be tested on the SF-1000 rocket engine, developed by SpaceForest. The tests aim to evaluate the durability of the new nozzles under extreme conditions characteristic of rocket engine operation. Due to its resistance to high temperatures, low weight, and ability to maintain mechanical properties, CFRC is expected to significantly enhance rocket propulsion efficiency.

AGH staff and SpaceForest representatives discussing engine shielding at the SpaceForest facility.
AGH researchers and SpaceForest engineers in discussion about rocket engine shielding during their meeting at SpaceForest.

Significance of the collaboration for the space industry

The collaboration between AGH and SpaceForest, focused on CFRC technology development, is highly significant for the space industry. This technology, initially explored by NASA in the 1960s, was used in the Apollo program. In Poland, CFRC research was mainly conducted in the 1990s, with a focus on potential medical applications. The Lider XIII project gives Poland an opportunity to revisit CFRC research, this time with applications in the space, aerospace, and military industries, as well as other sectors.

AGH researchers and SpaceForest engineers reviewing a CFRC engine nozzle on the SF-1000 rocket engine.
AGH and SpaceForest teams review a CFRC nozzle installed on the SF-1000 engine during their meeting at SpaceForest.

Innovation and technology development at SpaceForest

During the meeting, SpaceForest representatives presented the company’s technological capabilities. Participants toured the production facility and learned about innovations in rocket engines. As a leading space technology company in Poland, SpaceForest is committed to developing advanced propulsion systems. The collaboration with AGH represents another step forward in advancing rocket technology in Poland.

Engineers completing the assembly of a test rocket body.
Engineers working on the final touches of the test rocket body at SpaceForest headquarters.
Interior view of the rocket production workshop at SpaceForest.
The rocket production workshop at SpaceForest, showcasing the advanced manufacturing processes involved in rocket assembly.

Potential of CFRC nozzles in propulsion systems

CFRC nozzles have unique thermal and mechanical properties. They could significantly impact the development of rocket propulsion systems. In addition to excellent heat resistance, carbon-carbon composite allows for complex geometries. This makes it ideal for components like rocket nozzles. Research on CFRC is gaining attention due to its potential and the growing interest in rocket technology. From 2010 to 2020, the number of scientific publications on CFRC increased more than fourfold. This indicates the rapidly expanding potential of this technology.

In addition to rocket nozzles, CFRC composites can be used in various rocket components. These include thermal shields, rocket bodies, and structural elements. Their lightweight and high-strength characteristics make them ideal for parts that endure extreme conditions during launch, flight, and landing. Because of these properties, CFRC could become a key material in future space missions. It has the potential to enhance both the efficiency and safety of rockets.

AGH researchers and SpaceForest engineers discussing a hypersonic rocket body made from carbon fiber fabric.
AGH and SpaceForest teams discussing the hypersonic rocket body constructed from carbon fiber fabric during their meeting.

Future collaboration prospects

The visit of Prof. Aneta Frączek-Szczypta and Dr. Maciej Gubernat to SpaceForest provided an excellent opportunity to discuss the next steps towards the commercialization of CFRC technology and its broader implementation. Both sides emphasized the importance of continued scientific and industrial collaboration, which will contribute to the development of Poland’s space sector. With support from the National Centre for Research and Development and the involvement of universities like AGH, Poland has a chance to strengthen its position in the global technological race, particularly in the field of advanced composite materials and rocket technologies.

Visitors touring the advanced electronics production area at SpaceForest.
Guests exploring the advanced electronics production area at SpaceForest, observing cutting-edge technologies in action.
Experts discussing the Clean Room ISO 07, used for advanced electronics production and payload recovery after suborbital flights.
A conversation about the Clean Room ISO 07 at SpaceForest, focusing on its role in advanced electronics production and payload recovery post-suborbital flights.

We are confident that this collaboration will lead to the successful implementation of CFRC technology. This will mark a significant milestone for the Polish space sector. SpaceForest is accelerating the commercialization of space flights (PERUN Rocket System), and this will soon become a reality. For more information, read the article on our collaboration with the European Space Agency.

It is also worth mentioning the SALTO project, under which SpaceForest is developing a propulsion system responsible for the “flip” maneuver of the Themis vertical take-off and landing rocket. The goal of the project is to test the vertical landing of a reusable first-stage rocket prototype, marking a pioneering step in Europe. SALTO will conduct cycles of flights, recovery, and re-flights of the first-stage rocket demonstrator. The CFRC material from AGH has the potential for use in this project. More details will be presented soon.

Composite Technologies at SpaceForest

Discover the innovative composite technologies developed by SpaceForest and explore their vast potential in aerospace applications. With cutting-edge advancements in materials science, SpaceForest is pushing the boundaries of what’s possible in rocket technology. To learn more about how these groundbreaking composites can revolutionize the industry, click here.

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