Rocket startup lightens the load with additive manufacturing

The Challenge​ 

bluShift Aerospace, a Brunswick, Maine-based startup, is advancing the future of rocket propulsion with engines powered by a novel carbon-neutral biofuel. In propulsion systems, efficiency is paramount – every gram saved in component mass translates to improved performance and broader mission flexibility. One critical element is the oxidizer valve body, which channels the liquid oxidizer into the solid biofuel during combustion. Traditionally, this part’s complex geometry required multiple precision-machined pieces, leading to labor-intensive assembly and fastening. bluShift sought a way to streamline this component, reducing its weight while also simplifying manufacturing. 

The Partnership​ 

To solve this challenge, bluShift partnered with Dr. Andrew Neils at the Roux Institute to pursue funding through the Maine Space Grant Consortium and NASA EPSCoR. Together with bluShift engineering leadership, Neils identified the oxidizer valve body as a prime candidate for redesign. Drawing on his background in materials science, Neils brought a structured approach to materials selection and design for additive manufacturing. The collaboration focused on replacing the traditionally machined, multi-piece valve body with a single, additively manufactured component optimized for performance, mass, and printability.​ 

The Outcome​ 

The team’s goal was to redesign the oxidizer valve body using generative design and additive manufacturing to reduce its weight and streamline manufacturing. The result was a consolidated component that reduced part count from 17 individual pieces to just one, eliminated fasteners, and cut more than 1.2 kilograms of weight. This design improvement represents an estimated $35,000 increase in payload revenue per launch, making it a powerful step toward more efficient, scalable launch systems.