Christian KUDISONGA, Ronan HUGHES, Josh SLOMAN, Michael SMART, Michael HEITZMANN
DOI Number: N/A
Conference number: HiSST-2025-364
Hypersonix Launch Systems (HLS) is an Australian start-up aiming to launch a 3D-printed hypersonic vehicle by the end of 2025. The vehicle’s structure, including both the engine and airframe, will predominantly utilize Inconel due to its high-temperature resistance. However, thermal modelling conducted by HLS identified a critical region within the engine intake that would be exposed to heat loads exceeding Inconel’s tolerance. To address this, HLS partnered with The University of Queensland to investigate the feasibility of manufacturing a ceramic matrix composite scramjet inlet- insert. Although the Ceramic Matrix Composite (CMC) crotch insert could have been fabricated entirely from a machined CMC plate, this method was deemed cost-prohibitive and time-intensive. Instead, the project focused on producing the component as close to near-net shape as possible, thereby minimizing the extent of final machining required. Several manufacturing challenges emerged that significantly influenced design decisions. The initial strategy employed the Polymer Infiltration Pyrolysis (PIP) process, selected for its simplicity and lack of requirement for ultra-high temperature furnaces. However, extended turnaround times between
specimen cycles and insufficient mechanical properties necessitated a transition to reactive melt infiltration. The manufacture of a flight ready scramjet inlet-insert was successfully demonstrated. In this paper we describe the development journey and summarise the findings.