qdonnellan
[1]: https://www.relativityspace.com/
[EDIT] If you're reading this and you work at Relativity, I'd love to know if you actually 3D print your nozzles...
The nozzle must be made out of graphite, the manufacturing of which is much more complicated than aluminum, so throw out the door any pre-conceived notions you may have that making any shape is possible. Our nozzle was a three-part component: the inner plug (think of one of those "nose suckers" you have to get boogers out of a baby's nose) and the outer nest in which the plug sat. Between the nest and the plug you have "struts" supporting the plug to allow for a gap (through which your fuel will be exhausted). The plug is secured to the nest via some high-heat epoxy.
So yeah, way more complicated than a single bell of graphite, which is probably the #1 reason why these haven't seen industry use (the cost of complexity must be weighed against the cost of inefficiency, both are important factors in any rocket application).
I am very interested in the "linear aerospike"[1] engine though, which would obviously have design implications on the rest of the spacecraft, but manufacturing a linear aerospike would be much simpler than what we attempted.
[1] https://en.wikipedia.org/wiki/Aerospike_engine [The main image]
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