The US Air Force has awarded Firehawk Aerospace a $4-million deal to develop 3D-printed rocket propellant designed to extend missile range.
The Texas-based startup is pursuing thermoplastic-based fuels, moving away from traditional solid propellants. The project supports a joint initiative by the Air Force Research Laboratory and SpaceWERX, aimed at advancing next-generation propulsion.
According to Firehawk, its additive manufacturing process makes rocket production safer, faster, and more versatile, enabling new designs and performance improvements that conventional methods cannot match. Unlike labor-intensive processes with long lead times, 3D printing delivers rapid iteration and precision.
The project is backed by the SBIR/STTR innovation program, which funds small businesses developing technologies with defense applications. Firehawk represents a new breed of suppliers that can quickly move prototypes to demonstrations, in contrast with the slower cycles of legacy defense firms.
The investment underscores the US military’s effort to integrate 3D printing into critical systems, balancing speed and reliability. In a related push, the US Army recently announced it is applying additive manufacturing to sustain tactical platforms, including squad vehicles and M777 155mm howitzers, reducing dependence on global supply chains.
