Ursa Major Expands 3D-Printed Missile, Engine Work

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2–3 minutes

Summary

Ursa Major said it is scaling 3D-printed rocket motors, hypersonic systems for U.S. military demand.

Why this matters

The work reflects a broader U.S. effort to expand missile production capacity and shorten manufacturing timelines for munitions and hypersonic systems. If successful, the approach could affect how quickly the military can adapt production to changing operational needs.

Ursa Major said it is expanding from propulsion into missile development, with a focus on 3D-printed solid rocket motors and liquid-fueled hypersonic systems.

Chief Executive Officer Chris Spagnoletti said the company unveiled its Havoc hypersonic missile in early 2026 as part of a broader effort to address U.S. munitions shortfalls. He said Havoc uses a 3D-printed propulsion system and is intended to be lower-cost and adaptable for air, ground, or vertical launch.

The Colorado-based company said it has produced hundreds of engines and motors and logged more than 135,000 seconds of hot-fire testing in less than a decade. It uses additive manufacturing, including metal printing, in both liquid rocket engines and solid rocket motors.

Co-founder Nick Doucette said Ursa Major applied its manufacturing approach to solid rocket motors after identifying bottlenecks in traditional production, particularly the metal tube structures used in motors. The company said its modular production lines can switch between motors from 2 inches to 22 inches in diameter without major retooling.

Ursa Major said it is producing solid rocket motors in Berthoud, Colorado, and expanding higher-volume production in Galeton, Colorado. Doucette said the company has made several hundred 2.75-inch motors for testing and development for the Advanced Precision Kill Weapons System, or APKWS, produced by BAE Systems. In 2024, the company won a Naval Energetics Systems and Technologies program contract tied to the Mk104 dual-thrust motor used in the Navy’s Standard Missile 2 and SM-6.

In hypersonics, Doucette said Ursa Major’s Hadley engine has flown 10 times on Stratolaunch’s Talon A testbed. He said the company later developed Draper, a 4,000-pound-thrust engine that uses hydrogen peroxide and rocket fuel instead of liquid oxygen, allowing longer storage and tactical use.

Ursa Major then developed Havoc in-house after deciding not to rely on an outside airframe partner, Doucette said. He said the company moved from concept to a flight-ready vehicle in about six months through work with the Air Force Research Laboratory.

The company said it has twice ground-launched a “Havoc Block 0” demonstrator under the Affordable Rapid Missile Demonstrator program. Spagnoletti said the next goal is a boosted hypersonic flight demonstration in 2027.

Ursa Major also operates a 3D-printing facility in Youngstown, Ohio, with final assembly and testing in Berthoud.

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