Ursa Major Propels U.S. Navy Missile Program With 3D Printing

Denver-based rocket innovator Ursa Major, a leading force in propulsion technology, has recently announced the company has secured a landmark contract with the US Navy’s Naval Energetics Systems and Technologies (NEST) Program. The collaboration aims to propel the Navy’s Standard Missile program into a new era of precision and reliability, strengthened by cutting-edge advancements in 3D printing technology. Additionally, through this partnership, the Navy will see the launch of new weaponry, specifically 3D-printed solid rocket motors (SRMs) built using Ursa Major’s Lynx approach to manufacturing.

Leveraging the recently unveiled Lynx, Ursa Major seeks a complete redesign of the Mk 104 dual-thrust rocket motor, the workhorse powering the Navy’s Standard Missile family. This component, critical for a diverse range of missiles, drives the SM-2, essential for surface-to-air defense; the SM-3, critical for ballistic missile defense; and the SM-6, a versatile anti-air, land, and sea missile. Notably, the SM-6 is the only multi-role missile capable of intercepting hypersonic threats – a growing concern for national security.

Launch of an SM-6, powered by the Mk. 104 dual-thrust rocket motor component. (Photo Credits: U.S. Navy)

Ursa Major’s Lynx approach tackles longstanding hurdles in SRM production by integrating 3D printing with a versatile tooling system. This method, encompassing a variety of additive manufacturing technology and techniques, promises to streamline the production process, slashing lead times and boosting overall reliability – crucial factors for rapid response capabilities. The use of 3D printing will prove especially beneficial, as manufacturing current versions of the Mk 104 dual-thrust rocket motor presents a significant challenge due to its complex and time-consuming processes. This bottleneck coincides with a critical period for the US Navy, as domestic demand for SRMs is surging, driven by the need to replenish stockpiles and support Ukraine’s ongoing conflict.