3D Printed Continuous Fiber Ablative Propulsion Elements

The cost, availability, and performance of ablative fiber-reinforced propulsion elements fundamentally limit capability in the aerospace systems. Legacy production methods suffer from manufacturing methods that heavily rely on manual processing and material systems that are not conducive to high-yield manufacturing, problems made more severe by highly cyclical demand. Mantis Composites is addressing these challenges using continuous fiber 3D printing and off-the-shelf materials used in substantial volume for commercial applications. This Direct To Phase II utilizes an extensive modeling, testing, and component development work plan involving three hot-fire test cycles to de-risk 3D printed ablative materials in solid rocket motor applications. Two different hot-fire test setups will test six individual components to prove out a wide range of motor sizes and motor components. In addition to hot-fire testing, Mantis Composites will perform an initial unit component run to inform future yield and production cost calculations for the 3D printed ablative component capability. The proposed manufacturing process entirely leverages existing and installed processing machines and equipment with only slight modifications to existing processing, enabling rapid scaling without substantial infrastructure or production-scaling cost. Approved for Public Release | 25-MDA-12052 (27 Mar 25)