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Precision Machining for a Plasma Jet Engine

RapidDirect machined high-temperature components for Sylphaero's electric plasma jet engine in 316 and 304 stainless steel and copper C110.

Precision Machining for a Plasma Jet Engine
Industry
Aerospace Industry
Process
CNC Machining
Materials
316 Stainless Steel & 304 Stainless Steel & Copper C110(TU0)
Parts
High-temperature engine components
Background

Components That Run Near 2000 °C

Sylphaero is building an electric plasma jet engine aimed at decarbonising aviation. Local temperatures near 2000 °C force material choices and tolerances that ordinary machining support cannot absorb.

Key challenges
Extreme Temperature

Parts sit in a flow that reaches 2000 °C locally.

Stainless and copper grades had to hold pressure and temperature together.

Different materials had to fit without losing alignment at temperature.

How the Engine Components Were Machined

Machinability was reviewed per material before cutting, and the components were machined to the tolerances the assembly required.

Material Review

Material Review

316 and 304 stainless and copper C110 were checked for machinability and finish.

CNC Machining

CNC Machining

Components were machined to the tolerances the plasma engine assembly required.

Tolerance and Fit Checks

Tolerance and Fit Checks

Parts were measured against the assembly envelope before shipment.

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Components Delivered for Testing

Sylphaero took delivery of the machined set and continued assembly and test work.

After delivery

Machining Support for an Early-Stage Engine

The parts arrived to spec, which kept the prototype assembly on its test schedule.

Precision machining support for a first-generation plasma engine
Components Delivered for Testing

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