Advancing the Future of Aerospace and Defense in the U.S.: Inside Ursa Major’s Flexible and Scalable Manufacturing Innovation

Propulsion, the force that drives objects forward, is catalyzing the use of modern technologies, such as putting satellites into space, GPS, and countless everyday tools we take for granted. This technology is also integral for national security, in order to maintain the strategic edge in a world where space control is as important as dominance over land, sea, and air. Ursa Major is transforming rocket engine production with scalable additive manufacturing to secure the future of U.S. aerospace and defense technology. The past year in particular has been full of meaningful milestones as the team executes on its mission. In March, the Ursa team successfully launched the Hadley rocket engine in a first flight that broke new ground reaching near hypersonic speeds in flight testing. The company also announced the opening of a new R&D facility in Youngstown, Ohio, expanding its manufacturing capacity and accelerating the development of new, critical materials used in making rockets like the next-gen solid rocket motors the Navy commissioned from Ursa in April. Well-positioned for its next stage of growth, the company welcomed industry veteran Dan Jablonsky as Chief Executive Officer to deliver cutting-edge propulsion solutions to its customers. “Propulsion is at the heart of rocket and satellite technology that comprises roughly half of both the launch cost and complexity tied to these systems,” says Bill Murray, Chief Product Officer of Ursa Major. “If propulsion systems vanished, were in short supply, or malfunctioned, the U.S. would leave allies vulnerable and embolden adversaries.” This isn’t a far-fetched, “what if” scenario. For decades, SpaceX has been the leading innovator reinvigorating U.S. competitiveness in the space race after NASA retired the Space Shuttle. By creating reusable rocket technology and reducing reliance on Russian propulsion technology, a new cohort of privately funded space companies have boosted the U.S. space program. In fact, if it were not for reinvigorated space innovation, China’s launch rate would be four times that of the U.S. today. Despite this progress, the U.S. is still lagging behind. The U.S. faces unsustainable missile consumption rates, taking years to replenish, while China advances quickly due to its long-term investment in military modernization. Since 2015, Ursa Major has been on a mission to accelerate U.S. aerospace and defense innovation — reimagining propulsion technology to ensure the U.S. and its allies can deter threats and remain vigilant in the coming century. By applying the lessons learned in liquid rocket engine production for space launch, the Ursa Major team has reimagined a solid rocket motor design and manufacturing approach through its unique process called Lynx. With Lynx, Ursa Major offers a revolutionary solution to America’s SRM shortage with a faster, more affordable process, leveraging 3D printing to manufacture inert components for multiple motors to meet customer needs and combat propulsion shortages. At the same time, Ursa Major has built its own in-house energetics capability to diminish reliance on an already-strained supply chain and to enable rapid development and scalability. Ursa Major’s Innovation in Manufacturing Propulsion Systems Inspired by SpaceX’s approach to rapid prototyping and vertical integration, Ursa Major is unique in how it designs, builds, and tests its products in one place, cutting costs and driving industry breakthroughs. The team is tackling aerospace and defense’s toughest challenges, starting with systems to protect against hypersonic missiles and solid rocket motors for various defense applications. Ursa Major’s first launch with Stratolaunch’s Talon-A1 marked a significant step forward in defense against hypersonic threats, among the most challenging today.

“Hypersonic deterrents can fly at different altitudes, throttle deep, undetected, and strike at any moment. To deter this threat, we need test beds, targets, and strike capabilities,” says Nick Doucette, Chief Operations Officer of Ursa Major. Since then, the Ursa Major team has secured four additional contracts from the Department of Defense and commercial aerospace agencies. New Manufacturing Techniques with High Engineering Velocity and Precision Unlike most manufacturers who have relied on increasing capacity of existing processes, Ursa Major takes a “clean sheet” approach, redesigning the process of rocket engine and rocket motor production for optimal performance from the ground up. Their engines — including Hadley — which powered Stratolaunch’s Talon-AI, are 3D-printed, allowing for more complex geometrical shapes, while cutting production time to a fraction of traditional manufacturing processes.

Developed in just 18 months by Ursa Major’s dedicated team, Hadley emerged as America’s first oxygen-rich staged combustion engine. Not only did it rival the best Russian technology that previously defined the market, but it also set a new benchmark for the industry. “This engine cycle, which burns kerosene and oxygen for unprecedented performance, was once thought impossible in the U.S.,” says Murray.

Ursa Major’s remarkable innovation speed was showcased yet again when they demonstrated the ability to go from design to static fire on a new motor platform in less than 30 days. Building on their success with liquid rocket engines, the team now aims to make an even greater impact with solid rocket motors, enhancing precision and performance essential for missile defense and rapid-response scenarios. From Bunker Beginnings to Industry Leaders From their humble beginnings in a windowless bunker, the small yet mighty team have grown into full-fledged leaders in rocket engines. Today, Ursa Major is over 230 people strong, with experts from every major flight capable liquid rocket engine development program in the last decade on their 90-acre campus in Colorado.

Standing at the edge of Ursa Major’s test facility, you can feel the ground shake as the Hadley’s 5,000-pound thrust engine roars to life. The engine, powering Stratolaunch’s hypersonic test vehicle, unleashes a deafening roar and a blazing plume of fire and gas — a powerful display of American engineering. Early Launches Ignite a Bright Future As global tensions rise, the need for advanced propulsion solutions is increasingly becoming crucial. Each launch doesn’t just send rockets into space; it pushes the limits of aerospace innovation in service of our country, evoking the same spirit that sent man to the moon in the 1960s. Ursa Major’s growth from a small team to a leading force in aerospace and defense showcases American ingenuity in its finest form. Their journey, driven by determination and creativity, illustrates how modest beginnings can lead to remarkable achievements. By leading innovation in the aerospace and defense categories, Ursa Major is working tirelessly to ensure America remains a global superpower and the land of the free. Follow Eclipse on LinkedIn or sign up for Eclipse’s Newsletter for the latest on the Industrial Evolution.Follow Ursa Major on LinkedIn, X, and Instagram, for more insight into what it means to power the future of defense and aerospace.