Traditional manufacturing techniques such as forging and machining have long been used to produce spacecraft components like rocket combustion chambers and nozzle liners. In recent years, additive manufacturing—commonly known as 3D printing—has gained significant attention for its potential to streamline production processes for these critical parts.
However, another technique known as metal spinning is proving to be a highly effective alternative, especially for creating large, circular aerospace components such as combustion chambers and nozzle liners.
This article explores the key advantages of metal spinning and explains why it stands out as a powerful solution for manufacturing in the aerospace and space exploration industries.
What is metal spinning?
Metal spinning is a unique manufacturing process that forms metal by directly shaping a solid metal blank into the desired shape. Unlike methods that carve parts from solid blocks or build them layer by layer, metal spinning efficiently uses material, minimizing waste. At the same time, it produces parts with the strength and quality comparable to those machined from forged metal.
Why is metal spinning the preferred method for manufacturing spacecraft components?
For producing large, round parts such as rocket nozzles and combustion chamber liners, metal spinning has demonstrated clear advantages over both additive and subtractive manufacturing techniques.
With a proven history of reliability and performance, metal spinning stands out as a leading process in the aerospace industry—a market that USMS proudly supports.
Here are some of the key benefits that make metal spinning the superior choice…
8 Advantages of Metal Spinning
When it comes to manufacturing large, round spacecraft components, advanced metal spinning offers eight clear benefits over other methods.
Strength and Durability
Metal spinning produces parts with properties comparable to forged metals. By precisely controlling grain flow and size, the hoop strength of spun parts can improve by about 3 to 4%. This added strength is critical for applications where even small gains significantly impact performance. Through skilled shaping, metal spinning captures the benefits of forging, ensuring the reliability required in space exploration.
Material Savings
Unlike subtractive processes that remove material from solid blocks, metal spinning directly forms the metal into its final shape. This minimizes waste, reduces costs, and supports sustainability—a crucial factor in modern manufacturing. Some customers have seen material usage cut by as much as nine times.
Faster Production
Metal spinning creates seamless parts without welds or joints. This eliminates time-consuming steps like welding rings together, resulting in much faster production cycles.
Complex Geometries
Metal spinning provides precise control, enabling the creation of intricate, complex shapes with exceptional accuracy. Skilled craftsmen manipulate the metal on spinning lathes to meet the tight tolerances critical in aerospace, where every detail matters.
Form Consistency
Advanced metal spinning consistently produces perfectly round parts, unlike methods that weld sheet metal wraps. This ensures uniform material properties and superior roundness throughout the component.
Control Over Width
Our process allows customers to control the width of parts by flaring or closing the ends, offering versatility for various applications. For example, it can produce seamless tanks that are both lightweight and structurally robust.
Larger Components
USMS can manufacture parts up to 80 inches tall and wide—and even larger if needed. By comparison, typical 3D printing is limited to about 40 inches.
Wide Range of Metal Alloys
Metal spinning works effectively with numerous alloys including aluminum, titanium, stainless steel, and specialized aerospace metals. This versatility ensures compliance with stringent industry standards and delivers high-quality, high-performance components.
While metal spinning plays a central role in space component manufacturing, it is often complemented by subtractive processes like machining to achieve final precise dimensions and fine finishes.
Nonetheless, metal spinning forms the foundation of production, leveraging its unique advantages to deliver superior aerospace components.
What is the metal spinning process?
Metal spinning is a manufacturing technique where metals and alloys are exposed to intense heat and mechanical stress, shaping them by pushing the material to its physical limits.
This process demands careful precision, as even small deviations can greatly affect the quality of the finished part.
By integrating computer controls, precise calculations, and continuous monitoring, our engineers guarantee that every stage of metal spinning precisely follows the intended design specifications.
What does the future hold for advanced metal spinning?
Advanced metal spinning presents notable advantages over traditional manufacturing methods, making it especially suited for heavy-lift rockets and large-thrust engines.
With increasing demand for copper alloys across sectors such as rocket propulsion, renewable energy, and aerospace, efficient and economical use of materials is more important than ever.
Continuous innovation is driving efforts to scale up production, enabling the creation of larger, seamless components with greater efficiency.
Additionally, hybrid manufacturing approaches—integrating metal spinning with technologies like 3D printing and subtractive machining—hold promise for expanding capabilities and addressing the evolving requirements of modern industries.
USMS Metal Spinning Quality Control Process
To guarantee quality and precision throughout our manufacturing, we implement a series of rigorous steps, including:
Accurate measurement of dimensions and temperature controls
Comprehensive material testing and sampling
Detailed preparation procedures
Regular equipment maintenance and updates
The insights gained during production allow us to continuously identify opportunities for streamlining and enhancement.
Working closely with our customers is essential to eliminate unnecessary steps, integrate operations, and optimize part designs. Our goal is to make the manufacturing process simpler, more reliable, and highly efficient.
Is Metal Spinning the Right Choice for You?
When guiding customers in choosing between advanced metal spinning and other manufacturing methods, we take a consultative approach. Here’s how the process unfolds:
You share your part specifications, including dimensions, shape, performance needs, and assembly requirements.
Our manufacturing specialist evaluates the feasibility and potential challenges of producing your part using advanced metal spinning.
Design concepts and drawings are reviewed, and expert advice is provided on achievable outcomes and the advantages of metal spinning.
You assess the metal spinning solution against alternative methods, considering factors like cost, lead time, and performance to find the best fit.
Our expert collaborates with you to determine the most suitable manufacturing method and confirm whether advanced metal spinning meets your project goals.