A Major Milestone: DoD Launches Rocket with 3D Printed Motor

Published on November 8, 2024 by Julia S.

The United States Department of Defense (DoD) is no stranger to additive manufacturing. They have used AM to produce everything from hypersonic weapons to 3D printed barracks, and just this October, they awarded $4.5 million to ceramics 3D printing development. Now, with a new program called TACTILE (the Tactical Launch Effort program), they have been addressing the rising demand for low-cost, long-range suborbital energetics that can be rapidly produced. The Defense Innovation Unit (DUI), a unit within the DoD, launched the program, which aims to leverage advancements in dual-use commercial technologies for suborbital missions and ballistic targets by using additive manufacturing.

3D printed rocket motor

Unlike orbital spaceflight, when a spacecraft stably circles the earth at least once, suborbital spaceflight is when a spacecraft goes into space without completing an orbital revolution. Instead, the spacecraft is carried back to Earth, because it does not have enough velocity to escape into orbit. Why are suborbital spaceflights useful? They can be optimal for experimentation in low-gravity environments, testing spaceflight technology and of course, space rides for tourists.

A rocket from X-Bow Systems (Photo credits: X-Bow Systems)

One of the primary challenges of expanding suborbital launch capabilities is moving beyond reliance on liquid and cryogenic rocket fuels. These fuels produce large amounts of energy but require complex infrastructure and are costly to handle. Additionally, their volatility poses safety risks. That’s why the TACTILE program is turning to solid propellants created through advanced manufacturing.

The TACTILE program has three major objectives. One is to launch the commercial prototype modular launch solution with an integrated advanced manufactured solid propellant (AMSP) printed first-stage motor. Then, demonstrate an AMSP printed motor in a relevant flight environment and evaluate the scalability and flexibility of the technology. Finally, evaluate the system design’s ability to support affordable, high-cadence, flight applications across diverse mission objectives using a commercially available launch service.

Successful Launch with 3D Printed Rocket Motor

On September 12, 2024, the TACTILE program reached a key milestone when X-Bow Systems, the primary performer on contract, successfully launched a single-stage rocket using 3D-printed propellant. The XB-32 rocket reached an altitude of 32,000 feet and a speed of Mach 1.2, powered by an AMSP motor. The flight demonstrates the potential of additive manufacturing in rocket propulsion, as well as the potential for significant cost savings. Since then, X-Bow Systems has successfully launched a third flight with the XB-32 motor on October 22.

The DIU and the Space and Missile Defense Command collaborated to make the launch possible. The test allowed them to evaluate how AMSP-printed rocket motors could reduce labor costs, safely transport and store fuel and enhance operational efficiency. TACTILE is a testament to the advancement of additive manufacturing technology that supports collecting critical in-flight performance data.

One of X-Bow Systems’ successful rocket launches with its 34” Advanced Manufactured Solid Rocket Motor (Photo Credits: United States Army)

“The successful demonstration of 3D-printed propellant through the TACTILE program is a major step forward in delivering low-cost, rapidly deployable suborbital solutions, including in hypersonics,” said Major General Steve Butow, DIU Space Portfolio Director. “This achievement showcases the power of additive manufacturing to reduce costs and boost efficiency while underscoring the critical role of collaboration between DIU and commercial partners in driving innovation for future mission success.”

*Cover Photo Credit: US Armys