Italian rocket and missile producer Avio is increasing its manufacturing of stable rocket motors (SRMs) to satisfy rising demand from the US Division of Protection (DoD). The Pentagon’s annual funds requests for missile and munitions procurement, in addition to associated analysis and growth, elevated from $9 billion in 2015 to $30.6 billion in 2024.
In response to CEO Giulio Ranzo, Avio at the moment produces between 200 and 300 rockets yearly at its Colleferro facility. This capability is about to extend threefold within the subsequent 4-5 years to assist US efforts to restock its home inventories and provide missiles to Ukraine and Israel.
Avio can be constructing a US-based manufacturing web site to strengthen provide chains and diversify sourcing choices in response to business consolidation. Since Northrop Grumman acquired Orbital ATK in 2018, the US has had solely two main SRM producers: Northrop Grumman and Aerojet Rocketdyne.
This transfer follows information in July that Avio partnered with Raytheon Applied sciences (RTX) to construct a US industrial base for crucial SRMs. Avio additionally beforehand signed a take care of the US Military to develop and prototype an SRM for surface-to-air purposes.
Whereas it’s unclear whether or not Avio will leverage additive manufacturing to scale its SRM capability, it actively makes use of 3D printing to supply propulsion programs. Notably, the corporate possesses Velo3D Sapphire 3D printers which fabricate high-strength, corrosion and temperature-resistance components in nickel-based alloy supplies.
Moreover, Raytheon is a widespread adopter of additive manufacturing. The Virginia-based missile submitted 1,441 3D printing-related worldwide patent household (IFP) purposes between 2001 and 2020, second solely to Common Electrical (GE).
Avio to increase SRM manufacturing for the DoD
This excessive demand for SRMs within the US is at the moment coupled with a scarcity of home suppliers, inflicting the DoD to show to worldwide producers to high up manufacturing capability.
Ranzo lately advised Protection Information that Avio will initially work to satisfy US demand at its Colleferro facility earlier than opening the brand new US manufacturing web site. He said it would take roughly two extra years to qualify its SRM merchandise in Italy. The agency claims this strategy will probably be quicker and safer than ready for the development and qualification of the brand new facility.
For over 50 years, Avio has produced stable, liquid and cryogenic propulsion programs for tactical navy missiles. It expanded its attain within the US market in 2022 with the launch of Avio USA, the agency’s US subsidiary.
Notably, Avio produces elements for the Aster 30 surface-to-air missile, which is especially operated by French, Italian and British militaries. The corporate has additionally designed, developed and certified the solid-propellant rocket motor of the brand new CAMM-ER air protection missile in a contract with MBDA. Moreover, its core area enterprise presents the Vega launcher, which has put 120 satellites into orbit over the past 12 years.
3D Printing Propulsion Programs
Avio may flip to its 3D printing capabilities to ramp up SRM manufacturing. Final 12 months, the corporate acquired a Sapphire XC 1MZ 3D printer and an unique Sapphire 3D printer. These programs are used within the growth and manufacturing of the corporate’s propulsion programs.
Avio reportedly chosen Velo3D’s know-how because of its skill to manufacture high-quality components with optimized geometries, making certain superior efficiency. By means of the large-format laser powder mattress fusion (LPBF) 3D printers, the corporate seeks to optimize design high quality and scale back the time to marketplace for its merchandise.
Velo3D claims that the design freedom supplied by the Sapphire 3D printers permits Avio to attain beforehand unattainable geometries. This reportedly reduces weight whereas enhancing efficiency and enhancing reliability for extra environment friendly propulsion elements.
3D printing missiles
Different firms are 3D printing missile programs to satisfy rising demand from the US DoD. As an example, rocket engine producer Ursa Main is working with the US navy to scale SRM manufacturing utilizing its 3D printing-powered Lynx platform.
Final month, the agency turned an inaugural recipient of the Workplace of Strategic Capital’s (OSC) funding to strengthen home protection provide chains. Utilizing this funding, Ursa Main will mature its SRM 3D printing capabilities and design, manufacture, and take a look at a brand new SRM prototype.
It was additionally introduced earlier this 12 months that Ursa Main had signed a contract with the US Navy to design, manufacture, and take a look at a 3D printed stable rocket motor for the Customary Missile (SM) program. This mission seeks to develop a brand new 3D printable design for the Mk 104 twin rocket motor, which powers the SM-2, SM-3, and SM-6 missiles.
Equally, Aerojet Rocketdyne was awarded a $22 million DoD contract to supply a 3D printed hypersonic propulsion system prototype. The corporate expects to ship the prototype inside 36 months. It’s going to streamline the manufacturing workflow by consolidating the important steps of scramjet manufacturing.
The L3Harris Applied sciences subsidiary is growing the prototype for the DoD’s Rising Additive Manufacturing Maturity for Airbreathing Hypersonics (GAMMA-H) problem. This programme kinds a part of the Pentagon’s efforts to establish and develop new manufacturing processes for hypersonic weapons.
Elsewhere, US Protection agency Lockheed Martin is at the moment 3D printing key elements for its new Mako hypersonic missile. Steel additive manufacturing is getting used to supply the jet-fired missile’s steering part and fins, unlocking time and cost-savings within the course of. The 3D printed missile steering part is reportedly ten occasions quicker to supply and simply 1/tenth the fee than utilizing standard manufacturing strategies.
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Featured picture exhibits a US Navy SM-6 missile. Photograph by way of the US Navy.