Firehawk Aerospace has completed the first flight test of an additively manufactured GMLRS-class Firehawk Analog, a 3D-printed hybrid rocket engine system.
The hybrid rocket system achieved a vertical ascent of over 18,000ft, exceeding the speed of sound, after launching from a purpose-built mobile platform.
Showcasing directional stability and thrust performance, the flight test emphasizes the adaptability, affordability, and swift production made possible by hybrid engines and additive manufacturing, said Firehawk
Founded in 2019 by Ronald Jones, Will Edwards, and Steve Edwards, the Dallas, USA-headquartered Firehawk develops energetics systems for defence applications. The company conducts static fire and flight tests at two facilities in West Texas, including a 30-square-mile launch range.
Firehawk’s approach aims to address challenges in conventional solid rocket motor supply chains, which typically require years for production. The company’s hybrid rocket engines feature a rapid manufacturing timeline measured in weeks rather than years, leveraging proprietary 3D-printed propellant technology branded as 3D-Ultra.
The technology enables customizable combustion ballistics and throttleable engines with reduced development lifecycles. Firehawk’s proprietary energetic feedstock enables long-term storage and rapid, on-demand propellant production, accelerating the sustainment of munition stockpiles for both domestic and international operations.
“This milestone proves that hybrid propulsion systems, when paired with advanced additive manufacturing, have a real place in the future of tactical systems,” says Will Edwards, CEO, Firehawk Aerospace. “To design, develop and launch the first-ever GMLRS form-factor hybrid propulsion system underscores the strength and innovation of our engineering team and the scalability of our technology.”
The company is expanding its manufacturing capabilities with a new facility under construction in Lawton, Oklahoma. The 40,000 square foot facility, supported by a US$22 million state and federal funding package, is being built on 320 acres of land near Fort Sill and is expected to create 100 new jobs when operational.
The test is part of an ongoing Phase III Small Business Innovation Research contract with the US Army Applications Laboratory(AAL). Firehawk will next flight test its Javelin-class and Stinger-class analogs, which are designed as drop-in solid rocket motor replacements for existing Department of Defense weapon systems.
The company’s propulsion systems are designed to optimize mission profiles with extended range, reducing risks to soldiers while maintaining strategic advantages. Firehawk has also established strategic partnerships with companies including Fairlead, which specializes in containerized mission modules for shipboard, shore-based, and autonomous operations.
