Firehawk Aerospace has secured a $4 million Tactical Funding Increase (TACFI) award from AFWERX to further develop its hybrid additive manufacturing technology for solid rocket propulsion. The funding supports the U.S. Air Force’s drive to modernize missile and launch vehicle capabilities with scalable and cost-effective propulsion systems.
Firehawk’s Mission: Scalable Solid Rocket Propulsion via Additive Manufacturing
Founded in 2019 and headquartered in Dallas, Texas, Firehawk Aerospace is developing a new class of solid rocket motors (SRMs) using a proprietary hybrid manufacturing process that combines 3D printing with traditional casting techniques. The goal is to produce safer, more reliable motors with extended range and rapid production timelines.
The awarded TACFI contract—an extension of a prior Small Business Innovation Research (SBIR) Phase II agreement—will enable Firehawk to scale up its propulsion systems for tactical and strategic applications. According to company statements and AFWERX documentation, the project will focus on increasing motor energy density and burn efficiency while leveraging the design flexibility of additive manufacturing.
“This funding allows us to accelerate development of our extended-range propulsion systems,” said Will Edwards, CEO of Firehawk Aerospace. “It validates our approach of combining additive manufacturing with high-performance propellants.”
Why Additive Manufacturing Matters in Rocket Propulsion
Traditional SRMs are constrained by complex tooling requirements and long lead times. By contrast, Firehawk’s approach uses additive manufacturing—specifically fused deposition modeling (FDM)—to print internal grain structures directly into the motor casing before casting in the propellant. This method enables:
- Highly customized burn profiles through tailored grain geometries
- Reduced part count and simplified assembly
- Improved safety via inert pre-cast components
- Rapid iteration cycles for prototyping or low-rate production
The ability to digitally design and print complex internal geometries offers significant advantages over traditional cast-and-bore methods used in legacy SRMs like those found in AIM-120 AMRAAM or M270 MLRS rockets. Moreover, the technique may allow integration of thrust vectoring or dual-pulse configurations without major redesigns.
Tactical Funding Increase (TACFI): Bridging Innovation Gaps
The TACFI program is part of the U.S. Department of Defense’s broader effort to transition promising technologies from early-stage R&D into operational capability. Administered by AFWERX—a technology accelerator under the U.S. Air Force—the TACFI mechanism provides follow-on funding up to $18 million per awardee when matched by private capital or government stakeholders.
Firehawk’s TACFI award builds on earlier SBIR Phase I/II contracts focused on validating their hybrid SRM concept at subscale levels. With this new tranche of funding, they aim to conduct full-scale static fire tests of extended-range motors suitable for air-to-surface missiles or small launch vehicles.
This aligns closely with USAF priorities around next-generation munitions such as Stand-in Attack Weapons (SiAW), Extended Range Weapons (ERW), and hypersonic glide vehicle boosters—all requiring compact yet high-thrust solid propulsion systems.
Operational Implications: From Tactical Missiles to Responsive Launch
If successful at scale-up testing, Firehawk’s technology could impact multiple mission areas:
- Tactical Strike: Longer-range SRMs for cruise missiles or loitering munitions like Gray Wolf or SiAW concepts
- Aerial Launch Systems: Boosters for air-launched small satellites under programs like ASLON or Tactically Responsive Space (TacRS)
- C-UAS & SHORAD: Compact interceptors powered by fast-burning SRMs with tailored thrust curves
- Sustainment & Logistics: Reduced storage hazards due to inert pre-cast components; easier field handling
The modularity enabled by digital design also supports rapid adaptation across platforms—an increasingly critical feature as adversaries evolve countermeasures faster than traditional acquisition cycles can respond.
Industry Context: Competing Approaches and Strategic Relevance
The U.S. military’s renewed focus on solid rocket motor innovation comes amid growing concerns over industrial base fragility following supply chain disruptions at legacy providers such as Aerojet Rocketdyne and Northrop Grumman Innovation Systems (formerly Orbital ATK). These incumbents dominate large-scale SRM production but face capacity bottlenecks when surges are needed—as seen during Ukraine-related restocking efforts.
Younger firms like X-Bow Systems and Ursa Major are also pursuing novel approaches using additive manufacturing or modular engine architectures. However, Firehawk distinguishes itself through its hybrid grain-printing method aimed specifically at tactical-class SRMs rather than orbital-class engines alone.
Next Steps: Testing Milestones Ahead in FY2024–2025
The next critical phase for Firehawk will be full-scale static fire testing under operationally relevant conditions—a key milestone likely scheduled within FY2025 based on typical TACFI timelines. Success there would open paths toward integration trials on testbed platforms or surrogate missiles via AFRL or Air Armament Center programs.
If validated through flight demonstrations within two years—a plausible scenario given prior subscale test successes—Firehawk could become a viable supplier not only for USAF but also Navy/Marine Corps vertical launch applications or even NATO allies seeking indigenous SRM capabilities.
