Rocket engine manufacturer Ursa Major has initiated construction of a new 400-acre solid rocket motor test facility in Weld County, Colorado, marking a major step forward in the company’s capacity to design, produce, test, and certify large solid rocket motor (SRM) systems, including those used in standard missile programs, supporting both national and missile defense priorities.
“This facility represents a major step forward in our ability to deliver qualified SRMs that are scalable, flexible, and ready to meet the evolving threat environment,” said Dan Jablonsky, CEO of Ursa Major. “It’s a clear demonstration of our commitment and ability to rapidly advance and expand the American-made solid rocket motor industrial base that the country needs, ensuring warfighters will have the quality and quantity of SRMs needed to meet mission demands.”
Supported by U.S. Navy investment and addressing an industrial base in need of modern SRM capabilities, Ursa Major is expanding production and building out physical test infrastructure to deliver capabilities more quickly and cost-effectively than legacy providers. Construction is already in progress, with testing expected to commence in Q4 2025.
State-of-the-Art Testing and Validation
The site will act as the primary testing and certification location for Ursa Major’s large-scale SRMs, supporting current and upcoming missile systems while accelerating production timelines. Engineered for safe, full-scale static firings and future qualification procedures such as drop and temperature storage testing, the facility enables validation of SRMs manufactured using the company’s Lynx manufacturing process—a software-driven, additive-enabled production system accommodating multiple motor sizes from 2–22” in diameter and diverse thrust profiles without requiring retooling.
This milestone follows an intensive year for Ursa Major’s SRM program. So far, the company has completed four successful SRM flight tests and over 450 static fires, showcasing both scalability and consistency across different systems. Highlights include multiple firings of a 5” diameter SRM validating the proprietary manufacturing process, several 10” diameter static fires of a highly loaded grain motor, and a series of static fires for a 2.75” HLG SRM, extending its range with the APKWS laser-guided system.
3D Printing Missile Systems
Ursa Major’s additive-enabled SRM program reflects a broader trend in the defense industry toward 3D printing propulsion components. For example, Italian rocket and missile manufacturer Avio recently announced plans to triple its production of SRMs over the next 4-5 years to address growing US demand.
While the role of additive manufacturing in this initiative hasn’t been confirmed, the company actively uses 3D printing to produce propulsion systems. The firm possesses Velo3D Sapphire 3D printers to fabricate high-strength, corrosion, and temperature-resistance parts in nickel-based alloy materials. Avio previously partnered with Raytheon to build a domestic industrial base for critical SRMs. It is now building a US-based production facility to strengthen supply chains and diversify sourcing options.
Elsewhere, US Defense firm Lockheed Martin is 3D printing key components of its new Mako hypersonic missile. Metal additive manufacturing technology is being used to fabricate the jet-fired missile’s guidance section and fins, unlocking significant time and cost savings. The guidance section is 3D printed ten times faster than conventional methods while being just 1/10th of the cost.
Work on Mako started in 2017, with the missile now at readiness level six plus, meaning it is ready for production. Weighing 1,300 pounds, it has been externally fit-checked on F-35, F/A-18, F-16, F-15, and P-8 aircraft, with internal fit-checking completed on the F-22 and F-35C fighters. Its solid rocket motor (SRM) can accelerate Mako to Mach 5.
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Featured photo shows Construction of a new 400-acre solid rocket motor test facility in Weld County, Colorado. Photo via Ursa Major.
