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How one rocket startup is developing 3D-printed rocket engines for testing

Tom Cross

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I had a rare opportunity to visit Rocket Crafters, a small rocket company located in Cocoa, Florida, just 10 miles from the Kennedy Space Center, that is developing and testing what is known as ‘hybrid rocket engines’. These 3D printed engines are born in Colorado from a custom-made printer because none exist on the market that’s large enough to print these rocket engines that DARPA contracts them to build, with a $600,000 investment.

Press gathered inside Rocket Crafters control room to speak to the team. (Tom Cross)

After the hybrid fuel grains are printed, they’re shipped to Rocket Crafters in Florida where they are further processed by wrapping them in carbon for additional strengthening and then test fired. The company is testing three engines per week at an industrial location in the city of Cocoa. The only requirement the City has for testing these engines is to keep the noise level below a certain decibel, over concerns of disruption to neighboring residential.

Multiple small unwrapped 10-second burning test-engines on a shelf for future testing. (Tom Cross)

The engines, called fuel grains, are tubes made of ABS plastic, the same material LEGO are made of. The fuel grains are so safe, in fact, they can fly with them on airplanes as a carry on. They are specially shaped for the use of burning smoothly as a rocket engine, something only a printing process could form, which is a patented invention by Ronald Jones. The fuel grain needs an oxidizer in order to burn through, and without that, there’s really not much you can do with them because they’re just a tube of plastic.

When I arrived at Rocket Crafters the day of the test, I asked if I could set up my launchpad cameras to capture the flame of the engine during the test fire. Due to safety concerns over their oxidizer tanks that were already full, the team kindly advised against doing so. The oxidizer is nitrous oxide, also known as laughing gas at the dentist. Needless to say, it probably would have been incredibly funny had it sprung a leak while I was setting up my camera. The whole test stand sits on the back of a flat-bed trailer that’s ratcheted down to the concrete and protected by mobile steel walls on three sides.

CEO Sid Gutierrez, a former Space Shuttle Pilot, and Shuttle Commander touted the safety aspects of their rocket engine. “What you won’t see are cryogenics, bi-propellant liquid fuel engines, no signs saying explosives,” he said during the video conference. Rocket Crafters are carving their slice into the new wave of affordable launches for small-scale cube satellites and have grand plans of creating their own rocket called Intrepid consisting of multiple hybrid rocket engines burning simultaneously.

They brought me into their testing facility to showcase their fuel grains, carbon wrapping process, and most importantly a 10-second test fire of one of the engines from inside their control room. During the test, the engine could be heard through multiple block walls and doors as if it was just 10 feet away. The building didn’t shake, the sound was intense, though. The video on the screen doesn’t do it justice. The whole experience was pretty awesome.

Rocket Crafters still has a bit of work to do trying and testing new components before they’re ready to launch but they’ve already begun making prototypes of their full-scale engine. The day I was there, engineers were testing a nozzle made of a material they hadn’t tried before. “You don’t see many 15-person companies developing a rocket,” said Robert Fabian, SVP of Propulsion.

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SVP of Propulsion explains the components inside the test-tube. (Tom Cross)

I’m no rocket expert, I’d be a rocket scientist instead of a photographer if so, but I learn a lot by doing this. I think this particular hybrid rocket engine would be perfectly suited for a prosumer market of amateur rocketry, especially considering how safe they are and non-toxic to the environment. The few amateur rocket enthusiasts I’ve asked about hybrid engines said they’d be great to have after they fix the flaws of hybrid engines.

Here’s a video of one of their engine tests:

https://youtu.be/BVPxbdkC1y8

Tom Cross

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Tesla Semi futuristic sci-fi acceleration sound will never get old

Videos that capture the Semi moving at speed are most notable due to their sheer cool factor.

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Credit: Tesla Owners Silicon Valley/X

The Tesla Semi is not yet in mass production, but the company has accumulated over 7.9 million miles across its test fleet. With Tesla using the Semi for its operations, it is no surprise that sightings of the Class 8 all-electric truck have been abounding. 

These sightings from Tesla enthusiasts vary, but those that capture the the Class 8 all-electric truck moving at speed are most notable, possibly due to their sheer cool factor.

Tesla Semi’s Roar

There is something that just stands out with the Semi, particularly on the road. While the Semi does not have the Cybertruck’s brutalist, angular design, it is still very striking because it’s such a massive machine that moves far too quietly for its size. This is, of course, one of the reasons why the vehicle also becomes extra noteworthy when it fires up its electric motors and accelerates.

Take this video from Tesla Owners Silicon Valley, for example, which shows the all-electric hauler accelerating while pulling what appears to be a full load. In these situations, the Tesla Semi actually becomes audible, but unlike traditional diesel-powered truck, the Class 8 all-electric truck “roars” with its own, unique futuristic, sci-fi sound. In such situations, one could feel the Semi’s raw power, which comes from its three independent motors on its rear axles.

Tesla Semi Ramp

Tesla has been promoting the Semi quite a bit as of late, and recent reports have suggested that the company is putting in a lot of effort to prepare the vehicle for its production in Nevada. Tesla’s Careers website has gone live with over 80 Semi-related job openings recently as well, and a recent report has suggested that Tesla has ramped the Semi’s factory workers in Nevada to over 1,000 employees.

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The company has even shared an update video of the Semi factory’s progress near Giga Nevada, as well as the design of the vehicle’s new logo. The Semi’s updated logo is quite interesting as it features elements from the Tesla Model 3’s first logo, which was unveiled way back in 2016.

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Elon Musk jokes he will join Mr Beast’s “100 Men vs 1 Gorilla” challenge

It’s a good sign, if any, that the overworked Musk is becoming a bit more lighthearted again.

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Credit: Elon Musk/X

Following the first quarter Tesla earnings call, CEO Elon Musk seems to have become a bit more relaxed—relaxed enough to joke about fighting a gorilla with 99 other people, at least.

It’s a good sign, if any, that the overworked Musk is becoming a bit more lighthearted again and not too busy picking fights with politicians on social media.

The Viral 100 Men vs 1 Gorilla Challenge

Over the weekend, a post on social media platform X went viral. The post itself was quite simple, with user @DreamChasnMike stating that he thinks 100 men could beat one gorilla. “Everybody just gotta be dedicated to the sh*t,” the X user joked. The post exploded on the platform, garnering 284 million impressions as of writing.

The silly question also triggered a massive debate about whether 100 men would really stand a chance against a literal gorilla. Some users even lamented that the premise was a sign of male hubris. Nevertheless, the question proved to be a fun topic on X, with some more dedicated users even posting simulated videos of what the “100 Men vs 1 Gorilla Challenge” could look like. 

Mr. Beast and Elon Musk Join In

The premise is quite similar to other viral videos from noted YouTube creator Mr. Beast, so it was no surprise that edited images of Mr. Beast YouTube thumbnails with “100 Men vs a Gorilla” also started spreading on the social media platform. Mr. Beast, who tends to be game to such silly ideas, actually reposted the edited image, joking “Need 100 men to test this, any volunteers?”

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In true Elon Musk fashion, the Tesla and SpaceX CEO noted that he would join the challenge. “Sure, what’s the worst that could happen” Musk wrote in his post on X. Musk’s reply triggered quite a few laughs on X, with some stating that the world probably still needs the CEO.

While silly, Musk’s comment and his recent, more frequent posts about his companies’ products like Starlink and Grok have been received well by his supporters. Over the past months, after all, Musk has been very political and quite confrontational on social media. With Musk soon taking a step back from the Department of Government Efficiency’s (DOGE) daily operations, however, it seems like X will soon get a more tempered and lighthearted Elon Musk once more.

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Possible first glimpse of Tesla “Model 2” affordable car in Fremont Factory

The models that Tesla will release in the coming months will resemble the company’s current lineup.

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Image Credit: @metgodinwilderness7130/YouTube

During the Q1 earnings call, Tesla VP of Vehicle Engineering Lars Moravy set expectations on the design of the affordable models that the company is expected to launch this 2025. As per the Tesla executive, the models that Tesla will release in the coming months will resemble the company’s current lineup.

Drone footage from the Fremont Factory earlier this month might have provided the EV community its first potential glimpse at Tesla’s affordable cars–fondly dubbed by EV fans and analysts as the “Model 2” or even “Model Q”–or at least their components and overall shape.

The Sighting

Tesla watcher and drone operator Met God in Wilderness, who has been posting aerial videos of the Fremont Factory for years now, recently shared some footage from his drone flyovers this month. While the Fremont Factory was abuzz with activity as usual, a couple of rather strange vehicles were quickly spotted by EV watchers on social media.

During the drone operator’s flyover on the 17th, for example, an unfinished vehicle could be seen parked next to what appeared to be fully-built Model S and Model Y units. What was especially interesting was the vehicle’s roof, which seemed to be slightly narrower than the Model Ys around it. Based on the video, at least, the vehicle seemed to be shaped like a crossover as well.

Footage from the 24th of April also proved quite interesting, with the drone operator capturing footage of another cryptic vehicle. Unlike the mysterious, unfinished, crossover-esque car spotted on the 17th, this particular unit seemed to have a more sloping rear, at least based on the shape of its covering.

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What Lars Moravy Said

In Tesla’s Q1 2025 Update Letter, Tesla noted that “plans for new vehicles, including more affordable models, remain on track for start of production in the first half of 2025.” Tesla also noted that the new vehicles will utilize aspects of its next generation and its current platforms. They will also be produced on the same manufacturing lines as its present vehicle lineup, likely the Model Y and Model 3. 

During the earnings call itself, Moravy specifically stated that the new models that would come out in the next months would resemble the company’s current vehicles. They will, however, be affordable. “Models that come out in next months will be built on our lines and will resemble, in form and shape, the cars we currently make. And the key is that they’ll be affordable, and you’ll be able to buy one,” Moravy stated.

Watch the drone operator’s footage from April 17 below.

The drone operator’s footage from April 24 can be viewed below.

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