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How one rocket startup is developing 3D-printed rocket engines for testing

Tom Cross

Published

7 years ago

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I had a rare opportunity to visit Rocket Crafters, a small rocket company located in Cocoa, Florida, just 10 miles from the Kennedy Space Center, that is developing and testing what is known as ‘hybrid rocket engines’. These 3D printed engines are born in Colorado from a custom-made printer because none exist on the market that’s large enough to print these rocket engines that DARPA contracts them to build, with a $600,000 investment.

Press gathered inside Rocket Crafters control room to speak to the team. (Tom Cross)

After the hybrid fuel grains are printed, they’re shipped to Rocket Crafters in Florida where they are further processed by wrapping them in carbon for additional strengthening and then test fired. The company is testing three engines per week at an industrial location in the city of Cocoa. The only requirement the City has for testing these engines is to keep the noise level below a certain decibel, over concerns of disruption to neighboring residential.

Multiple small unwrapped 10-second burning test-engines on a shelf for future testing. (Tom Cross)

The engines, called fuel grains, are tubes made of ABS plastic, the same material LEGO are made of. The fuel grains are so safe, in fact, they can fly with them on airplanes as a carry on. They are specially shaped for the use of burning smoothly as a rocket engine, something only a printing process could form, which is a patented invention by Ronald Jones. The fuel grain needs an oxidizer in order to burn through, and without that, there’s really not much you can do with them because they’re just a tube of plastic.

When I arrived at Rocket Crafters the day of the test, I asked if I could set up my launchpad cameras to capture the flame of the engine during the test fire. Due to safety concerns over their oxidizer tanks that were already full, the team kindly advised against doing so. The oxidizer is nitrous oxide, also known as laughing gas at the dentist. Needless to say, it probably would have been incredibly funny had it sprung a leak while I was setting up my camera. The whole test stand sits on the back of a flat-bed trailer that’s ratcheted down to the concrete and protected by mobile steel walls on three sides.

CEO Sid Gutierrez, a former Space Shuttle Pilot, and Shuttle Commander touted the safety aspects of their rocket engine. “What you won’t see are cryogenics, bi-propellant liquid fuel engines, no signs saying explosives,” he said during the video conference. Rocket Crafters are carving their slice into the new wave of affordable launches for small-scale cube satellites and have grand plans of creating their own rocket called Intrepid consisting of multiple hybrid rocket engines burning simultaneously.

They brought me into their testing facility to showcase their fuel grains, carbon wrapping process, and most importantly a 10-second test fire of one of the engines from inside their control room. During the test, the engine could be heard through multiple block walls and doors as if it was just 10 feet away. The building didn’t shake, the sound was intense, though. The video on the screen doesn’t do it justice. The whole experience was pretty awesome.

Rocket Crafters still has a bit of work to do trying and testing new components before they’re ready to launch but they’ve already begun making prototypes of their full-scale engine. The day I was there, engineers were testing a nozzle made of a material they hadn’t tried before. “You don’t see many 15-person companies developing a rocket,” said Robert Fabian, SVP of Propulsion.

SVP of Propulsion explains the components inside the test-tube. (Tom Cross)

I’m no rocket expert, I’d be a rocket scientist instead of a photographer if so, but I learn a lot by doing this. I think this particular hybrid rocket engine would be perfectly suited for a prosumer market of amateur rocketry, especially considering how safe they are and non-toxic to the environment. The few amateur rocket enthusiasts I’ve asked about hybrid engines said they’d be great to have after they fix the flaws of hybrid engines.

Here’s a video of one of their engine tests:

https://youtu.be/BVPxbdkC1y8

Tom Cross

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Tesla owner highlights underrated benefit of FSD Supervised

Published

1 month ago

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January 31, 2025

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Credit: Tesla

Elon Musk has been pretty open about the idea of FSD being the difference maker for Tesla’s future.

If Tesla succeeds in achieving FSD, it could become the world’s most valuable company. If it doesn’t, then the company would not be able to reach its optimum potential.

FSD Supervised’s safety benefits:

  • But even if FSD is still not perfect today, FSD Supervised is already making a difference on the roads today.
  • This was highlighted in Tesla’s Q4 2024 Vehicle Safety Report.
  • As per Tesla, it recorded one crash for every 5.94 million miles driven in which drivers were using Autopilot technology.
  • For comparison, the most recent data available from the NHTSA and FHWA (from 2023) showed that there was one automobile crash every 702,000 miles in the United States. 

FSD user’s tale:

  • As per an FSD user’s post on social media platform X, FSD Supervised was able to help him drive a relative to a medical facility safely even if he was exhausted.
  • During the trip, the driver only had to monitor FSD Supervised’s performance to make sure the Tesla operated safely.
  • In a vehicle without FSD, such a trip with an exhausted driver would have been quite dangerous. 
  • “This morning, Tesla FSD proved to be an absolute godsend. I had to take my brother-in-law to the hospital in Sugar Land, TX, which is 40 miles away, at the ungodly hour of 4 AM. Both of us were exhausted, and he was understandably anxious about the surgery.
  • “The convenience of sending the hospital’s address directly from my iPhone to my Tesla while still inside my house, then just a single button press once inside, and 40 miles later we were precisely in front of the hospital’s admissions area.This experience really underscores just how transformative this technology can be for society,” Tesla owner JC Christopher noted in his post.

Don’t hesitate to contact us with news tips. Just send a message to simon@teslarati.com to give us a heads up.

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Tesla Optimus “stars” in incredible fanmade action short film

Published

2 months ago

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January 14, 2025

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Credit: @SoKrispyMedia/YouTube

There are few things that prove an enthusiast’s love towards a company more than a dedicated short film. This was highlighted recently when YouTube’s SoKrispyMedia posted a 10-minute action movie starring Optimus, Tesla’s humanoid robot, as well as several of the company’s most iconic products. 

The video: 

  • Shot like a Hollywood action flick, the video featured a rather humorous plot involving a group of thieves that mistakenly targeted a Tesla Model 3 driver. 
  • The Model 3 driver then ended up speaking to Tesla for assistance, and some high-octane and high-speed hijinks ensued.
  • While the short film featured several Tesla products like the Model 3, Superchargers, and the Cybertruck, it is Optimus that truly stole the show.
  • Optimus served several roles in the short film, from an assistant in a Tesla office to a “robocop” enforcer that helped out the Model 3 driver.

Cool inside jokes: 

  • The best Tesla videos are those that show an in-depth knowledge of the company, and SoKrispyMedia definitely had it. 
  • From the opening scenes alone, the video immediately poked fun at TSLA traders, the large number of gray Tesla owners, and the fact that many still do not understand Superchargers.
  • The video even poked fun at Tesla’s software updates, as well as how some Tesla drivers use Autopilot or other features without reading the fine print in the company’s release notes.
  • The video ended with a tour de force of references to Elon Musk products, from the Tesla Cybertruck to the Boring Company Not-a-Flamethrower, which was released back in 2018.

Check out SoKrispyMedia’s Tesla action short film in the video below.

Don’t hesitate to contact us with news tips. Just send a message to simon@teslarati.com to give us a heads up.

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Tesla releases Cybertruck metal key card—because why not?

Published

2 months ago

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December 31, 2024

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Credit: Tesla Shop

Tesla definitely seems to be determined to release the coolest lineup of accessories for its coolest vehicle. As could be seen in an update to the Tesla Shop, the electric vehicle maker has now launched a metal key card for the Cybertruck—because why not?

Cybertruck keys:

  • The Cybertruck, similar to Tesla’s other vehicles, is shipped with a regular key card. 
  • The vehicle could also be accessed and locked through a phone key. 
  • As per the Cybertruck’s Owner’s Manual, the all-electric pickup truck is capable of supporting a total of 19 keys.

The Cybertruck’s Metal Key Card:

  • Tesla’s Cybertruck Metal Key Card functions much like the vehicle’s regular key card, but it is finished using premium stainless steel
  • As per Tesla’s description of the item: 
  • “Convenient, durable, versatile. The Cybertruck Metal Key Card is a premium stainless-steel alternative to our traditional plastic key cards, making it easy to access your Cybertruck without your Phone Key. Ideal for when your phone is unavailable or when sharing your vehicle with a friend or valet.”
  • The Cybertruck Metal Key Card costs $60.
  • In comparison, the Cybertruck’s regular key card is sold for $40.
  • The Cybertruck Metal Key Card comes with the metal key card itself, as well as a bifold key card wallet.

Tesla Cybertruck merch push:

Don’t hesitate to contact us with news tips. Just send a message to simon@teslarati.com to give us a heads up.

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