- Description
-
DISC Alloys helps build bimetallic rocket engines faster and makes them more efficient than anyone else; thanks to our redesigned cold spray nozzle and single step process
Aerospace parts need to be strong and light but building them is time-consuming and expensive.Our modified cold spray nozzle has a resolution of 1mm and a deposition rate of 20 kg/hour (we achieve this by shooting metal powder at supersonic speed) which saves 90% of the manufacturing time for bimetallic combustion chambers (combustion chambers are the manufacturing bottleneck for rocket engines) and drops costs by at least 30-40% while DISC generates 70% gross margins. Speed allows for multiple iterations and learning resulting in:
increased thrust from design optimisation
decreased weight through streamlined parts
Through the use of bimetallic parts, manufacturers can have more efficient engines. Altogether, this means more payload, revenue and profit. Our calculations indicate a 1% increase in efficiency for the Falcon Heavy rocket results in 14,000 kg of fuel saving which is worth $20-25M in extra payload revenue. The result: DISC Alloys is a total game changer for the rocket industry.Cold Spray with our nozzle is a platform technology with multiple end markets. We believe we can offer superior thermal management performance through seamlessly combining copper and other metals together for multiple industries like satellite parts eg PCM chambers and support structures. Further cold spray can take advanced materials (high entropy alloys) that cannot be re-heated/melted, and now can be used to make high performance parts for aerospace and automotive applications. With our new nozzle we can go even further and make precision parts at speed, which is extremely difficult for existing cold spray manufacturers.
- Number of employees
- 2 - 10 employees
- Company website
- https://www.di-sca.com
- Industries
- Advanced manufacturing Airlines, aviation & aerospace
- Representation
- Immigrant-Owned Small Business
Recent projects
5-Axis Additive Metal Printer: Software Testing and Validation
DISC Alloys Inc is in the final stages of developing software for their cutting-edge 5-axis additive metal printer. The project aims to ensure the software's reliability and efficiency through comprehensive systems integration testing and validation. The primary goal is to identify and rectify any software issues that could affect the printer's performance. The rigorously test will do the following -test the low level firmware to gain confidence in reliability -validate performance of the mechanical system, motors, and sensors -calibrate and tune actuators and sensors -test, configure, and simulate controls software in Mastercam -system integration testing of coordinated motion to validate tool path execution This project provides learners with an opportunity to apply their knowledge of software testing methodologies and systems integration. The tasks include creating test plans, executing tests, and documenting results. By the end of the project, learners will have gained hands-on experience in validating complex software systems within a manufacturing context.
Heat Exchanger Gasket Optimization
DISC Alloys Inc is experiencing issues with the gaskets in their heat exchangers, leading to frequent failures and slowing down development. The goal of this project is to identify the root causes of these gasket failures and propose a viable solution to enhance their durability and performance. Students will apply their knowledge of materials science and mechanical engineering to analyze the current gasket materials and design. They will conduct a thorough investigation into the operating conditions and stress factors affecting the gaskets. The project will involve researching alternative materials and designs that could improve the reliability of the heat exchangers. By the end of the project, students will gain practical experience in problem-solving and optimization within an industrial context.
Latest feedback
Project feedback
Project feedback