The Impact of FDM 3D Printing on Model Rocketry

Introduction

Building or even just launching a model rocket is something that can get a lot of people hooked on aerospace. From my own personal experience, I can tell you that it is thrilling to see a model rocket fly hundreds of feet into the sky right before your eyes. But DIY model rocketry was not always as easy as it is today. Previously, all parts of the rocket had to be bought pre-made or painstakingly built, taking half of the fun out of  building and launching the model rocket. 3D printing changed this. Integral parts of the rocket that had to be bought, such as fins or nosecones, could be designed and manufactured in your own home. Some, with a powerful enough motor in hand, go to the point of 3D printing the entire body tube of the rocket (nose cone and fins included). 

Chapter 1: History of Model Rockets

In 1954, Orville Carlisle and his brother, Robert designed the first model rocket motor. With the space race well on its way, people all around the US were getting interested in space and rocketry, which led to an increase of people looking to build their own model rockets. Model Missiles Incorporated (MMI) was the first model rocketry company in the United States, founded by G. Harry Stine in 1957. Soon after, Estes Industries was founded by Vernon Estes in 1958 in order to manufacture rocket motors for MMI. Today, estes is still the largest producer of model rocket motors, which has allowed many people to get access to model rocketry as a hobby. 

One of the most integral parts of the rocket is its nose cone, but making them was challenging before 3D printing. Anyone that wanted to make their own nose cones made them from materials like balsa wood, plastic, or paper. They either shaped balsa wood by hand using sandpaper and carving tools to achieve the desired aerodynamic form, bought plastic nose cones or made them using plastic bottles, or made nose cones out of paper by cutting and rolling the paper into a conical shape, then reinforcing it with glue or a sealant. These methods required more manual skill and time compared to what 3D printing now offers.

Chapter 2: With 3D Printing

3D printing has allowed for both the speed and precision of making model rockets to increase. What previously had to be bought or handmade could much more easily be designed on a computer and then 3D printed. Additionally, 3D printing allows for further modification and personalization of model rocket parts, while oftentimes being cheaper than buying one and faster and more exact than making them by hand. Not only can 3D printing allow for rapid prototyping, but it can also allow for more complex designs (think different fins or nose cone shapes). Furthermore, 3D printing allows for intricate parts that cannot be bought and are very hard to build by hand, like thrust vectoring systems or air brakes, to be made, further advancing model rocketry and the concepts that are taught by building a model rocket. Moreover, the skills used to design these rocket parts can help those interested in engineering in the future, as almost every single engineering firm uses the same or similar programs for the purpose of designing new solutions and products. 

Chapter 3: The Future

As 3D printing becomes cheaper and more popular, model rocketry will become more accessible. Additionally, different types of filament can allow for many advancements in model rocketry, such as PLA aero and ASA aero helping to create a lighter, stronger rocket, water-soluble supports allowing for the easy production of complex designs, and flexible filaments like TPU allowing for the creation of very impact-resistant rockets. Advancements in 3D printing could even allow for ENTIRE rockets to be made at home, without any parts other than the motor needing to be bought. 

I know that without 3D printing, I would not be as interested in, nor as able to build model rockets.​​ The next era of model rocketry will be a great one, with many advancements made, all because of 3D printing.