NASA-Developed Printable Metal Can Take the Heat

NASA has engineered a game-changing printable metal called GRX-810, designed to withstand extreme heat up to 2,000°F for a year under intense stress. Developed at Glenn Research Center in Cleveland, Ohio, this heat-resistant alloy is crafted for 3D printing, enabling stronger, lighter parts for rocket engines and jet turbines. Unlike other affordable alloys that fail quickly, GRX-810 opens new possibilities for space exploration and aviation by making high-performance components cheaper and easier to produce.

The Heat Challenge in Aerospace

Rocket and jet engines operate in brutal conditions, with temperatures hitting 1,900°F to 2,400°F, pushing metals to their breaking point. Standard alloys crack under such heat or are too costly for 3D printing, limiting designs and raising expenses. Engineers often used complex cooling systems or expensive metals to keep parts intact, slowing innovation in spacecraft and aircraft. Finding an affordable high-temperature alloy for 3D printing metal was a major hurdle for advancing aerospace technology.

Crafting GRX-810

NASA’s team began with a blend of nickel, cobalt, and chromium for strength. To enhance heat resistance, they coated tiny metal powder particles with ceramic oxides, creating an oxide dispersion strengthened alloy. This process locks defects in place, preventing deformation under heat and stress. Using computer simulations, they tested 30 variations in weeks, refining the formula efficiently. A method called resonant acoustic mixing ensured even coating, making the powder ideal for 3D printed engine components.

Why GRX-810 Stands Out

GRX-810 excels in durability, lasting 1,000 times longer than typical printable alloys at extreme temperatures. It thrives in mid-range heat (1,900°F to 2,400°F), perfect for rocket engine parts like nozzles and combustors. Its 3D printing capability allows complex shapes, such as lightweight lattice structures or built-in cooling channels, reducing weight while managing heat. NASA’s tests in hot-fire engine conditions confirm GRX-810 performs reliably in real-world scenarios.

Revolutionizing Aerospace Applications

This aerospace metal alloy is set to transform rocket engines for NASA’s Artemis missions and future Mars explorations, where heat resistance ensures reusable parts. In aviation, GRX-810 can enhance jet turbines, allowing hotter operation for better fuel efficiency and lower emissions. It also suits hypersonic vehicles traveling above Mach 5, where extreme heat is a constant challenge. Beyond space, this printable metal could improve power plant turbines or high-heat industrial tools.

Partnerships and Commercial Use

Elementum 3D, based in Erie, Colorado, manufactures GRX-810 under a NASA license, producing batches from small amounts to over a ton. Their collaboration with NASA Glenn Research refines production for broader use. Early adopters are testing it in turbines and rocket nozzles, verifying its strength. This partnership shows how NASA’s innovations move from labs to industries, making 3D printed engine components more accessible.

Impacts Beyond Aerospace

GRX-810 lowers the cost of high-heat parts, easing supply chain reliance on rare metals. In defense, it strengthens missiles and ICBMs by withstanding intense conditions. For energy sectors, it boosts turbine efficiency, supporting cleaner power generation. By enabling affordable, complex designs, this heat-resistant alloy drives sustainability and performance across industries, aligning with global goals for greener technology.

What’s Next for GRX-810

NASA is scaling up tests, using directed energy deposition to print larger rocket engine parts. Researchers aim to tweak GRX-810 for even higher temperatures or lighter weights. Partnerships with companies like Elementum 3D will expand its applications, from aerospace to manufacturing. As 3D printing grows, this aerospace metal alloy could redefine how we build for extreme environments.

At the end of the day, GRX-810 isn’t just another new metal—it’s a game-changer. For decades, engineers have struggled to balance strength, cost, and heat resistance in rocket and jet engines. Now, with this printable alloy, they finally have a material that can take the heat without breaking the budget.

What makes it even more exciting is the flexibility of 3D printing. Instead of sticking to old designs, engineers can experiment with lighter shapes, built-in cooling systems, and smarter parts—all while knowing the material will hold up under extreme stress. That means faster innovation and more reliable machines.

This isn’t just about rockets flying farther or jets running more efficiently—it’s about opening doors. From powering cleaner energy on Earth to making space travel more practical, GRX-810 has the potential to reshape industries. And because it’s designed with long-term durability in mind, it makes technology more sustainable too.

Why This Breakthrough Matters

With space missions and aviation pushing for efficiency, high-temperature alloys like GRX-810 are critical. They make rockets reusable and jets more fuel-efficient, cutting emissions in a warming world. NASA’s work at NASA Glenn Research not only fuels exploration but also drives innovation on Earth. By solving heat challenges, GRX-810 paves the way for faster, cheaper, and greener advancements in technology.