US rocket program: Successful launch with 3D-printed propulsion system

As the commercial space sector evolves, the U.S. Department of Defense (DoD) is responding to the growing demand for cost-effective, long-range suborbital propulsion systems that can be produced quickly. To meet this need, the Defense Innovation Unit (DIU) has launched the Tactical Launch Effort (TACTILE) program, which aims to leverage advances in commercial dual-use technologies for suborbital missions and ballistic targets.

A key objective of the TACTILE program is to move away from liquid and cryogenic rocket propellants, which offer high energy densities but require complex infrastructure and pose safety risks. Instead, the programme relies on solid propellants that are optimized through commercial innovations in the field of 3D printing. The aim is to shorten production times and increase flexibility in the manufacture of rocket engines.

A significant milestone in the program was reached on September 12, 2024, when X-Bow Systems, the prime contractor, successfully launched a single-stage rocket with a 3D-printed solid-fuel engine. The XB-32 reached an altitude of 9,753 meters and a speed of Mach 1.2. This event highlights the potential of additive manufacturing technologies in rocket propulsion and aerospace defense by enabling cost-saving and efficient production methods.

“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.”

The TACTILE program continues to foster collaboration between DIU and commercial partners to integrate additive manufacturing technologies in space. Through these collaborations, the DoD should be able to develop versatile, cost-effective and responsive solutions for future defense requirements.