Firehawk Aerospace, a US defense startup, has secured a $4-million US Air Force contract to create 3D-printed solid rocket propellants that could increase missile range.
Unlike conventional fuels, Firehawk is developing thermoplastic-based propellants to meet the needs of a program run by the Air Force Research Laboratory and SpaceWERX, the Space Force’s innovation unit.
The company explained that its additive manufacturing approach enables safer, more adaptable, and more efficient propulsion systems. While traditional rocket production depends on slow, labor-heavy methods, 3D printing allows faster prototyping, more complex designs, and enhanced performance potential.
Funding comes through the SBIR/STTR program, which supports small businesses advancing defense-related technologies. Firehawk exemplifies a new generation of agile suppliers capable of moving from concept to testing far more quickly than traditional contractors.
This contract highlights the Pentagon’s drive to adopt advanced manufacturing for speed and resilience, ensuring US forces remain adaptable in contested environments. Similar efforts are underway across the services — in September, the US Army confirmed it is using 3D printing to produce key parts for systems like infantry squad vehicles and M777 lightweight howitzers without relying on distant suppliers.
