White Sands Missile Range, NM – As the commercial space sector evolves, the Department of Defense (DoD) is responding to the rising demand for low-cost, long-range suborbital energetics that can be rapidly produced. To meet this need, the Defense Innovation Unit (DIU) launched the TACTILE (Tactical Launch Effort) program, which aims to leverage advancements in dual-use commercial technologies for suborbital missions and ballistic targets.
Central to the challenge of expanding suborbital launch capabilities is moving beyond the use of liquid and cryogenic rocket fuels. While these fuels deliver high energy, they require complex infrastructure, are costly to handle, and pose safety risks due to their volatility. The TACTILE program is set to provide additional solutions by tapping into commercial innovations in solid propellants to meet defense needs.
The TACTILE program has three primary objectives: demonstrate launch of the commercial prototype modular launch solution with an integrated advanced manufactured solid propellant (AMSP) printed first stage motor; demonstrate an AMSP printed motor in a relevant flight environment and then evaluate the scalability and flexibility of the technology; and evaluate system design capability to support affordable, high-cadence, flight applications across diverse mission objectives using a commercially available launch service.
This TACTILE effort allowed for the demonstration of an affordable, high-cadence, flight applications for future diverse mission objectives. On September 12, 2024, in a key milestone for the TACTILE program, X-Bow Systems, the primary performer on contract, successfully launched a single-stage rocket using 3D-printed propellant. The XB-32 rocket reached an altitude of 32,000 feet and a speed of Mach 1.2 and was powered by an AMSP motor. This shows the potential of cutting-edge technologies like additive manufacturing in rocket propulsion and aerospace defense applications provide a new potential capability with the potential for significant cost savings.
The launch was made possible through a collaborative effort between DIU and the Space and Missile Defense Command (SMDC) to evaluate AMSP-printed rocket motors to reduce labor costs, safely transport and store fuel, and enhance operational efficiency. This initiative, which also supports the advancement of additive manufacturing technology and the collection of critical in-flight performance data, underscores the collective progress of the aerospace industry.
"The successful demonstration of 3D-printed propellant through the TACTILE program is a major step forward in delivering low-cost, rapidly deployable suborbital solutions, including in hypersonics," said Major General Steve Butow, DIU Space Portfolio Director. "This achievement showcases the power of additive manufacturing to reduce costs and boost efficiency, while underscoring the critical role of collaboration between DIU and commercial partners in driving innovation for future mission success."
As the TACTILE program continues to evolve, it will further position the DoD to leverage commercial innovations like additive manufacturing, in space and aerospace, enabling more versatile, cost-effective, and rapid response solutions for future defense needs.