Rocket engine startup Ursa Major enters solid-rocket motor business

Recognizing a desperate need of the military to ramp up production of solid rocket motors after much of its missile stockpile has been depleted by President Biden’s large gifts to the Ukraine, the rocket engine startup Ursa Major has now announced it is entering solid-rocket motor business.

Describing the solid rocket motor [SRM] market as “plagued by a broken supply chain and an overextended industrial base,” the Colorado startup today announced its plans to use its 3D printing techniques developed for liquid rocket engines to speed production of solid-fuel propulsion systems. Ursa Major has received several contracts from the Air Force Research Laboratory for its work on a new rocket engine for heavy space launch vehicles, as well as a hypersonic engine.

“Traditional SRM providers rely on production lines that are difficult to re-tool, expensive to ramp up, and dependent on a significant workforce to operate,” the company said in a press release touting its “new approach” to manufacturing, dubbed Lynx. “Ursa Major is offering a new way to scale production of SRMs,” Ursa Major CEO Joe Laurienti said in the press release. “Lynx meets the defense industry’s need for a faster, cheaper, scalable, and flexible SRM production process that results in better-performing solid rocket motors.”

The article also notes that at present the military is dependent on only two companies for new solid rockets, Northrop Grumman and Aerojet Rocketdyne (now L3Harris). The article also notes that it could take anywhere from five to eighteen years for these companies to replenish the depleted stocks.

The bottleneck however has brought several new players into the field, with the military eager to issue contracts to these new players. This decision by Ursa Major is thus a very good one.

A congressman acts to limit competition in solid rocket motor production

We’re here to help you! Congressman Duncan Hunter (R-California) in March introduced a new bill that requires U.S. companies building solid rocket motors to purchase the oxidizer from within the U.S.

That oxidizer, ammonium perchlorate, is only available from one Utah company, a company that also happens to belong to a member of the Washington establishment.

Some in industry are arguing the legislation is an earmark to help a now struggling business — American Pacific, owned by the Huntsmans of Utah — with political ties to the Trump administration. Jon Huntsman, former two-time Republican presidential candidate, is tapped to be the next ambassador to Russia.

And if the legislation passes as part of the fiscal year National Defense Authorization Act, the business would be propped up, but potentially at the expense of a larger solid rocket motor industry and the U.S. government, sources interviewed by Defense News argued.

Essentially, this bill would give Jon Huntsman’s company a monopoly and would likely increase the cost of making solid rocket motors.

The article is very detailed. While on the surface it sure looks like a case of crony capitalism, it is a bit more complicated. Demand for ammonium perchlorate has dropped since the shuttle was retired, causing Huntsman’s company to struggle. While it could be argued that this bill is an effort to save this company as well as encourage new American companies to form, there are many factors described in the article that suggest this isn’t going to happen, including this tidbit:

The other factor is the price for [ammonium perchlorate] will improve naturally when the government has more demand in roughly six years when NASA’s Space Launch System kicks off in full and the nuclear missile fleet is refreshed, so a solution that is more temporary could be in order, several sources suggest.

Since it is doubtful SLS will ever “kick off in full,” it is unlikely that demand for solid rocket motor oxidizer will ever rise as predicted. A better solution would be for Congress to mind its own business and let the market function normally. There are other companies in Europe providing this oxidizer, and the competition would force Huntsman’s company (as well as other new American companies) to innovate to stay competitive.

Solid rocket motors for American rockets?

The competition heats up: Even as ULA and Blue Origin begin work building an American engine to replace the Russian engines on the Atlas 5 rocket, ATK is offering its solid rocket motors for both Atlas 5 as well as Antares.

The company’s sales pitch is that they can get their product ready faster and cheaper. And since they are merging with Orbital Sciences anyway, I will not be at all surprised if Antares ends up with ATK solid rocket motors for its first stage.

As for Atlas 5, this sales pitch is actually aimed at Congress, which could step in and force ULA to buy ATK motors instead of Blue Origin’s new engine, even if this switch is against the wishes of ULA. As foolish as this might seem, the politics of pork (ATK provides more jobs than Blue Origin) could make it happen.