US' 3D-printed hybrid rocket engine system passes first flight test

Source: interestingengineering
Author: @IntEngineering
Published: 8/29/2025
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Read original articleFirehawk Aerospace, a Texas-based company, has successfully completed the first flight test of its 3D-printed hybrid rocket engine system, called the GMLRS-class Firehawk Analog (GFA), under a Phase III SBIR contract with the U.S. Army Applications Laboratory (AAL). The test demonstrated the system’s directional stability and thrust performance, achieving a vertical ascent exceeding 18,000 feet and breaking the speed of sound. This milestone highlights the advantages of hybrid propulsion combined with advanced additive manufacturing, including adaptability, affordability, and rapid production capabilities.
The GFA test is the initial flight demonstration in a series under the AAL contract, with upcoming tests planned for Javelin-class and Stinger-class analogs designed as drop-in replacements for existing solid rocket motors in Department of Defense weapon systems. Firehawk emphasizes that their approach drastically reduces production cycles from weeks to hours and supports mobile manufacturing, enhancing force sustainment and ensuring a resilient, U.S.-controlled supply chain for critical energet
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energyrocket-engineshybrid-propulsionadditive-manufacturingaerospace-technologydefense-technology3D-printing