A new propulsion development effort focused on solid rocket motors with extended range capabilities is moving forward in the United States, following the award of a $4 million contract under the U.S. Department of the Air Force’s TACFI program to defense company Firehawk Aerospace. The project centers on optimizing rocket motor design using 3D-printed thermoplastic-based propellant, an approach that combines additive manufacturing with advanced energetics.
According to the press release, the contract, awarded through the Air Force’s Open Topic SBIR/STTR initiative in collaboration with AFWERX and SpaceWERX, supports technologies that address operational challenges in modern defense environments. By focusing on range optimization, the effort aims to improve the efficiency and flexibility of solid-fuel propulsion systems used in tactical and strategic applications.
The solution under development uses additive manufacturing techniques to produce custom geometries and formulations for solid rocket motors. This allows for safer, more flexible and higher-performing propulsion systems, as well as enhanced control over structural properties.
The goal is to demonstrate motors that not only offer increased range but also improve safety and supply chain resilience—factors that are increasingly critical in modern conflict scenarios.
By integrating flexible manufacturing methods with solid propulsion technologies, the project supports a broader defense trend toward modular, scalable systems that can be quickly adapted to mission needs. The initiative is also part of a push to reduce production timelines and logistical complexity for systems that are often difficult to scale or modify once fielded.
The Open Topic SBIR/STTR framework, launched in 2018, was designed to expand the scope of innovation funded by the Air Force. This specific contract reflects growing interest in propulsion technologies that can support evolving defense strategies without relying on legacy production models.
With development now underway, the resulting propulsion capabilities are expected to play a role in enhancing the range, responsiveness, and versatility of future defense platforms.
