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5-Axis Machined Rocket Engine Parts for LURA

RapidDirect turn-milled and 5-axis machined LOUIE's combustion chamber and engine components, holding ±0.07 mm and delivering the full set in seven days for the Race to Space competition.

5-Axis Machined Rocket Engine Parts for LURA
Industry
Aerospace Industry
Process
CNC Machining
Materials
Aluminum & Stainless Steel
Parts
Combustion chamber and engine components with oblique holes and grooves
Background

Why the LOUIE Engine Was Hard to Machine

LURA, the Leeds University Rocket Association, built LOUIE as its first engine for the National Race to Space Propulsion Competition. The parts had to be machined inside a two-week window, and several features, including the combustion chamber, had already been quoted as unmanufacturable by other shops.

Key challenges
Two-Week Delivery Window

Most machining centers quoted lead times that would have missed the competition deadline entirely.

The combustion chamber carried angled holes and curved grooves that needed multi-axis access in a single setup.

Tolerances on mating and flow-critical features left no room for re-clamping error or scrap.

How the LOUIE Engine Parts Were Machined

RapidDirect put a dedicated team on the Silverback project, re-checked the tolerances that risked scrapping, and machined the engine set with turn-mill and 5-axis operations.

Toolpath and Fixture Planning

Toolpath and Fixture Planning

Toolpaths for the angled holes and curved grooves were verified in CAM, and dedicated fixtures were built so each part runs in one clamping.

Turn-Mill and 5-Axis Machining

Turn-Mill and 5-Axis Machining

Turn-mill operations cut the primary geometry, then 5-axis work finished the flow features and threaded ports.

Inspection and Delivery to the Test Stand

Inspection and Delivery to the Test Stand

Every part shipped with a measurement report, and the full engine set reached LURA inside the seven-day window.

Explore CNC Machining

Seven Days From Drawing to Test Fire

The engine set arrived before the competition and LOUIE fired on the test stand with every part mated as designed.

After delivery

No Rework Before the Test Campaign

All parts fitted as intended on assembly, and the delivered surface finish came in above the team's specification, so LURA moved straight into its hot-fire campaign.

Delivered in 7 days with ±0.07 mm held on engine-critical features
Seven Days From Drawing to Test Fire

Customer perspective

RapidDirect not only committed to manufacturing all of our parts with only minor adjustments but also offered competitive costs that fit within our budget, all while ensuring strict adherence to our tight timelines.

Dom ButaTeam Member, Leeds University Rocket Association

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