{"id":5379,"date":"2026-11-11T04:59:38","date_gmt":"2026-11-11T04:59:38","guid":{"rendered":"https:\/\/daily-bullet.com\/?p=5379"},"modified":"2026-11-11T04:59:39","modified_gmt":"2026-11-11T04:59:39","slug":"army-research-leads-to-first-3d-printed-heavy-fuel-engine","status":"publish","type":"post","link":"https:\/\/daily-bullet.com\/?p=5379","title":{"rendered":"Army Research Leads to First 3D-Printed Heavy-Fuel Engine"},"content":{"rendered":"
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ADELPHI, Md. \u2014 Years of Army scientific research culminated in the successful flight demonstration of a 3D-printed heavy-fuel rotary-engine series-hybrid system, advancing power and propulsion science for future tactical unmanned aircraft systems.<\/p>\n

Researchers at the U.S. Army Combat Capabilities Development Command, known as DEVCOM, Army Research Laboratory, designed the advanced drone propulsion through its Versatile Tactical Power and Propulsion essential research program.<\/p>\n

\u201cThe program addresses critical power and propulsion challenges by advancing fundamental science that could enable drones to fly longer and faster, operate at higher altitudes, carry heavier payloads and perform in extreme environments while reducing logistics burdens,\u201d said Dr. Chol-Bum \u201cMike\u201d Kweon, DEVCOM ARL program manager. \u201cFor warfighters, the program has transitioned research findings to industry partners for maturation and integration into capabilities that could enable mid-sized drones to operate beyond line of sight, extending the reach of ground commanders and reducing risk to Soldiers.\u201d<\/p>\n

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ARL researchers used advanced computational fluid dynamics modeling and a clean-sheet design approach to address the challenges of efficiently burning heavy fuel in a rotary engine. The work improved fuel atomization and vaporization while minimizing compressed-air and fuel-vapor leaks.<\/p>\n

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\u201cThe use of advanced manufacturing, including 3D metal printing, allowed us to rapidly redesign engine components based on lessons learned through experimentation,\u201d Kweon said. \u201cIt enabled us to design an air-cooled engine that reduces propulsion-system size and eliminates the need for liquid coolant.\u201d<\/p>\n

Integrated with a novel 400-volt motor-generator system, the engine forms a heavy-fuel rotary-engine series-hybrid system designed to support vertical takeoff and landing operations in contested environments.<\/p>\n

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To demonstrate the propulsion system in flight, ARL worked with industry partners, including Griffon Aerospace, to develop an aircraft platform around the propulsion system. The novel series hybrid system powers the Group 3 midsized, unmanned aircraft system, Versatile Intelligence Controlled Tactical Operational Reconnaissance and Attack, or VICTOR UAS.<\/p>\n