SBIR-STTR Award

X-Bow Launch Systems and its partners have developed a feasible concept to additively manufacture solid propellant. This additive manufacturing method, adapted from existing scaleable processes, will reduce the lifecycle cost and improve the overall responsiveness of the X-Bow Launch Systems vehicle. The innovation is to adapt breakthrough manufacturing processes developed for the Li-Ion battery industry. A variation of high speed electro-spin and electro-spray will be adapted, simulated and tested to ensure they are optimized for the constituent, fuel, binders and oxidizers required for solid propellant. Markets and applications have been identified as part of the technology development, including both sub scale and full scale. This technology will move to TRL 4 level during the Phase I effort; a rapid Phase II plan to move the Technology to the TRL 6/7 range has been identified. Current estimates show a significant cost savings of ~$5M in the total flyaway cost of a small launch vehicle. Additionally, by incorporating this technology, the potential improvement to the performance of the X-Bow launch vehicle is ~30%.

To meet DARPA’s specified needs, X-Bow (pronounced “Crossbow”) will infuse advanced manufacturing (AM) methods to produce its small launch vehicle. The vehicle will be capable of rapid and affordable on-demand launch of small payloads. There are ample commercially available opportunities to infuse automated and AM techniques into tanks, nozzles, and other mechanical components. However, there is no readily adaptable or commercial method for additively manufacturing solid propellant. Therefore, X-Bow Launch Systems will lead the development and commercialization of the capability to ‘print’ solid rocket motor propellant. This AM method will address and lower affordability hurdles of a solid-propellant launch system, while at the same time increase its responsiveness. The AM method will handle all principle solid propellant constituents ( Fuel, Oxidizer, Binder, Cure Agent, Plasticizer and other additives. The AM method will be prototyped built and demonstrated through a Full Scale integrated ground test of a 30" diameter small launch rocket motor.