In a joint effort that could reshape the U.S. missile propulsion landscape, Raytheon and defense startup Anduril Industries have successfully completed a test of an advanced solid rocket motor using novel manufacturing techniques and energetic materials. The test represents a potential leap forward in domestic missile propulsion capabilities amid growing demand for long-range precision fires.
Successful Test Demonstrates Viability of New Propulsion Concepts
According to Raytheon’s announcement on May 13, 2024, the companies jointly tested a prototype solid rocket motor (SRM) that incorporated advanced manufacturing processes and next-generation energetic formulations. While specific performance metrics were not disclosed due to classification concerns, Raytheon stated that the test “met all objectives” and validated key design assumptions.
This marks the first major collaborative milestone between Raytheon (a division of RTX) and Anduril since their strategic partnership was announced in October 2023. The partnership aims to accelerate innovation in missile systems by combining Raytheon’s legacy expertise with Anduril’s software-defined weapons development model and digital engineering stack.
Advanced Manufacturing Techniques at the Core
The tested SRM reportedly leveraged additive manufacturing (AM) methods for both structural components and internal grain geometries—a technique increasingly explored across the defense industry for its ability to reduce lead times and enable complex designs not feasible with traditional casting or extrusion methods.
Anduril has previously emphasized its use of automated composite winding systems and rapid prototyping workflows through its Lattice OS software platform. These capabilities were likely key enablers in producing the experimental motor casing and nozzle assembly with reduced tooling costs. The integration of digital twin modeling also allowed for faster iteration cycles leading up to live-fire testing.
New Energetic Materials Could Boost Range and Thrust
In addition to structural innovations, the companies highlighted their use of “novel energetics”—a term typically referring to high-energy propellant formulations that offer improved specific impulse or burn rates over legacy ammonium perchlorate-based compositions.
While details remain classified, this could include new oxidizer blends such as hydroxylammonium nitrate (HAN), high-density composite propellants (HDCP), or even nano-energetic additives designed to enhance combustion efficiency while reducing signature or environmental impact. If successful at scale, these materials could enable longer-range missiles without increasing form factor—critical for systems like air-launched standoff weapons or shipboard vertical launch platforms constrained by canister size.
Strategic Implications Amid SRM Market Consolidation
The timing of this breakthrough is notable given recent concerns over U.S. solid rocket motor industrial base fragility. Following Northrop Grumman’s acquisition of Orbital ATK in 2018—and Lockheed Martin’s failed attempt to acquire Aerojet Rocketdyne—there are only two major prime contractors currently supplying SRMs for U.S. programs like Javelin, HIMARS/ATACMS/PrSM, SM-series interceptors, GMLRS pods, THAAD boosters, etc.
This duopoly has raised alarm within DoD circles about supply chain resiliency amid surging demand driven by Ukraine replenishment needs and Indo-Pacific deterrence posture shifts. By positioning itself as a disruptive entrant into this space through its alliance with Raytheon, Anduril may help diversify sources of propulsion technology while accelerating innovation timelines traditionally hampered by legacy production methods.
Potential Applications Across Missile Portfolios
The companies did not specify which weapon system this new SRM is intended for; however, analysts suggest it could support several near-term initiatives:
- Next-generation standoff weapons: For example JASSM-XR or future variants of the AGM-158 family seeking extended range via higher-efficiency motors.
- Tactical surface-to-surface missiles: Such as PrSM Increment variants requiring compact yet powerful boosters compatible with HIMARS/M270 launchers.
- Navy vertical launch systems: Where volume-constrained canisters benefit from increased thrust-to-weight ratios without redesigning shipboard infrastructure.
- AIR-to-AIR missiles: Future AIM-260 JATM derivatives may benefit from high-energy motors offering faster time-to-target against maneuvering threats at longer ranges.
- SAMs/Interceptors: Potential application in layered air defense systems where acceleration profiles are critical (e.g., SM-6 Block IB).
A Shift Toward Modular Digital Weapon Architectures
This test also reflects broader trends toward modularity in missile design—where propulsion units are treated as swappable components within digitally defined architectures rather than bespoke elements tied to one munition type. This aligns with DoD’s push toward open systems standards like MOSA (Modular Open Systems Architecture) across air-launched weapons portfolios starting FY2025 onward.
If proven scalable beyond prototyping stages, such digitally manufacturable motors could support rapid tailoring of munitions for mission-specific requirements—e.g., variable thrust profiles for urban vs open terrain strikes—or even enable field-replaceable booster modules integrated via common interfaces across services’ arsenals.
