Defense startup Firehawk Aerospace has been awarded a $4-million contract from the US Air Force to advance 3D-printed solid rocket propellants. The initiative, overseen by the Air Force Research Laboratory and SpaceWERX, is designed to expand missile range and boost performance using next-generation fuel technologies.
Firehawk is pioneering thermoplastic-based propellants, departing from decades of reliance on conventional solid fuels. By leveraging additive manufacturing, the company aims to deliver propulsion systems that are safer, more adaptable, and capable of higher output. The firm described its approach as a means to unlock “greater flexibility and performance” for the US military.
Traditional methods of producing rocket propellants involve complex, time-consuming processes that limit design innovation. With 3D printing, manufacturers can create intricate geometries, iterate faster, and streamline production timelines. These advantages are especially vital in modern conflict scenarios, where speed, reliability, and innovation directly impact mission success.
The investment comes through the SBIR/STTR program, which funds promising small businesses to accelerate technology development for defense use. Analysts say Firehawk embodies a new generation of startups able to deliver rapid solutions, complementing the slower, more rigid pace of legacy contractors. The move follows recent announcements by the US Army, which is using 3D printing to manufacture replacement parts for vehicles and artillery such as the M777 howitzer, underscoring the Pentagon’s growing reliance on additive manufacturing.
