Nice read. The fact that it is possible to 3d print metal parts that withstand temperatures and pressures of a rocket engine is so exciting. How expensive is it?
After the printing itself, one will have to remove to loose powder, which for small cooling channels in the walls of the combustion chamber is very challenging and time consuming.
After that, some post-processing may also be necessary. One process for achieving the greatest strength is hot isostatic pressing, when the part is baked in a furnace in a retort filled with a very high pressure inert gas.
Specifically for rocket engines, it is also desirable to have a layer with the high heat conductivity on the inside, typically made of a copper-based alloy, and the external structure from a higher strength material. This means either bi-metallic printing, which is a rather niche process, or some metal deposition process over the printed part.
In addition to this, there is usually quality control, for example, high resolution industrial computed tomography, to make sure that the invisible internal features have been fabricated and cleaned out correctly.
In addition to the additive steps, it will also be necessary to machine the features which are impractical or impossible to build sufficiently accurately.
Together, these steps add to a significant cost.
Some of the above processes can be seen in this video: https://www.youtube.com/watch?v=7pXEf0wHU1Y
3d printed titanium goes for 300-400 USD/kg, steel is a bit cheaper at ~150 USD/kg for most inconel grades.
And also the other engine mentioned isn't an aluminum one.
Inconel powder is also Not That Great for your health and at the particle-size the printers rocket companies use, you need full PPE to safely handle the loose powder floating about.
The machines themselves are also expensive. Think in the millions of USD. EOS, SLM, and Velo3D are key players in this market. They require a fair bit of space, and training to use correctly.
You probably need a mechanical engineer who is well-versed in materials science and has a tolerance for finicky machines that constantly breakdown.
Then you have the metal powders. Which, also potential million or two.
And then you have all the associated infrastructure needed. High voltage power. Gas (Nitrogen, Helium, Argon, etc etc) in the thousands of liters per month. Waste disposal. Safety (some alloys are flammable in their powder form). Climate control (the powders are sensitive to the environment. Humidity will quickly destroy your powder supply). Tooling (the base-plates metal printers used are machined from solid blocks of steel).
And last but not least, any of the post-printing work. Heat treat. Coatings. Analysis. CNC Machining.
3D Printing metal on industrial scales is a CAPEX intensive endeavor, and not for the faint of heart.
However, a bunch of places rent out time on those machines. Draw up your rocket, and get a quote. Price is generally cc^2 volume
Metal is not cheap. Make a few out of plastic to verify dimensions.
But don't forget that the laser sintering of metal powders might result in design constraints not present in plastic printing!
PCB mounting outlines can be exported from above 3D CAD and imported to EDA tools such as Altium and KiCAD; KiCAD is fine unless you're doing DRAM or PCIe. Same PCBWay and JLCPCB takes your design, and optionally assemble PCB with parts for you.
That should take you to first 2-3 working units at ~$500 and up to few dozen beta units with zero initial cost and much inflated unit costs, and I guess beyond that involves significant human resourcing and networking problems outside of PoC hardware scope.
For the electrical side, there are plenty of schematics online that you can try to copy or use as a starting point. And the CAD side can be a simple box with snap fits. I'd recommend OnShape if you're just starting out since it's the lowest barrier of entry, but Fusion 360 is also good. All in, it should be <$150 for the PCBs + Components + 3D Prints.
After you get the satisfaction of seeing your device charge from something you made, then you'll start getting the itch and find more excuses to make things.
Meaning that instead of thinking "how do I 3D print this?" you should be thinking "how do I manufacture this?"
Something as simple as making a drawing, specifying the material and quantity needed and then going on reddit/r/manufacturing and asking "how would I build 50 of these" can provide very useful answers, even if you have to do a bit of research later to understand what you've been told.