Sintavia Secures DoD Contract for Development of 3D-Printed Hypersonic Propulsion Systems

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It has long been evident that additive manufacturing knows no bounds. This has been demonstrated once more as Sintavia, reputed to be the first fully digital aerospace component manufacturer in the world, has secured a contract from the U.S. Department of Defense (DoD). Sintavia is tasked with producing parts for hypersonic propulsion using additive manufacturing techniques.

The term hypersonic pertains to speeds that surpass five times the speed of sound, starting at Mach 5, or more than 3000 mph. Such capabilities are integral for various uses such as long-distance ballistic travel and air-defense interceptor missiles. In the current state of global defense, enhancing hypersonic propulsion technology has become a crucial focus for the U.S. defense sector, a role Sintavia is poised to fill.

The DoD issued the contract as part of its Growing Additive Manufacturing Maturity for Airbreathing Hypersonics (GAMMA-H) initiative. Announced in October 2023 with a fund of $106.7M, it is a collaborative venture overseen by the Office of Secretary of Defense ManTech and the Naval Surface Warfare Center, Crane Division. The emphasis on additive manufacturing arises from its ability to produce precisely detailed geometries that traditional manufacturing methods cannot achieve, making it indispensable for advanced hypersonic projects.

The Florida-based Sintavia, which was also previously chosen to represent the AM supply chain in the AM Forward initiative and has backing from companies like Honeywell and Lockheed Martin, was thus a perfect fit due to its all-digital process. The company is known for using generative design to simulate, additively manufacturing, post-process, test and even certify complex mechanical components. It is particularly well-known as well in the aerospace and defense industries. The company was contracted through the S²MARTS OTA managed by National Security Technology Accelerator (NSTXL) and will be expected to “develop and prove the robust quality and operational processes needed to design and manufacture critical precision components needed for hypersonic flight” according to a press release.

“The GAMMA-H award represents an important step forward in developing and formalizing standard additive manufacturing processes that can be used across the industry for hypersonic production,” concludes Brian R. Neff, Sintavia’s Founder & CEO. “As the industry leader in this effort, Sintavia is uniquely positioned to work with the GAMMA-H project to successfully develop and validate these processes. We are grateful to the GAMMA-H team for their trust in Sintavia regarding this absolutely critical national security imperative.” The contract is expected to run through 2025.

What do you think of the news that Sintavia will be developing hypersonic engines as part of GAMMA-H with the DoD? Let us know in a comment below or on our LinkedIn,Facebook, and Twitter pages! Don’t forget to sign up for our free weekly newsletter here for the latest 3D printing news straight to your inbox! You can also find all our videos on our YouTube channel.

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