3D Printed Hypersonic Components Industry Research: Reach US$ 60.3 Million by 2031 and CAGR of 14.2%

The global market for 3D Printed Hypersonic Components is entering a phase of accelerated industrialization. The latest forecast from QYResearch projects market size to grow from US$ 24.1 million in 2024 to US$ 60.3 million by 2031, achieving a CAGR of 14.2% between 2025 and 2031. Missiles dominated revenue in 2024, while reusable hypersonic aircraft platforms are expected to account for a larger share by the end of the decade. North America currently leads in both manufacturing capacity and end-use demand, while Asia-Pacific and Europe are catching up rapidly with investments in additive manufacturing facilities and new material technologies.

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Leading Companies

Sintavia
Aerojet Rocketdyne
Renishaw
Ursa Major Technologies
Velo3D
Hermeus

Applications

· Missiles

· Aircraft

· Others

Classification

· Turbine Blades

· Satellite Propulsion Nozzle Segments

· Flight Components

· Others

Latest Market Data

· 2024 Market Size: US$ 24.1 million

· 2031 Market Size Forecast: US$ 60.3 million

· CAGR 2025-2031: 14.2%

· Key demand driver: Missiles remain the primary segment, with aircraft adoption rising

· Regional performance: North America leads, while Asia-Pacific and Europe accelerate adoption

2025 Industry Highlights

· Aerojet Rocketdyne: Awarded US$ 22 million under the GAMMA-H program to demonstrate a scramjet "Powder-in, Engine-out" prototype, streamlining manufacturing and reducing cost.

· Hermeus: Achieved the first flight of Quarterhorse Mk 1 in May 2025, a key milestone toward reusable hypersonic aircraft. Earlier in January, it activated the HEAT facility for propulsion testing.

· Ursa Major Technologies: Secured US$ 28.6 million from the Air Force Research Laboratory and a US$ 32.9 million Stratolaunch contract for 16 Hadley H13 engines, advancing hypersonic propulsion at scale.

· University and research initiatives: University of Arizona launched a US$ 5 million program combining 3D printing with machine learning to optimize alloys for hypersonic conditions.

· Materials innovation: Researchers successfully 3D-printed dark ceramics and advanced copper alloys for use in extreme-temperature environments such as leading edges and propulsion chambers.

· Reusable vehicles: The U.S. Department of Defense reported successful recoverable hypersonic test vehicle flights in late 2024 and early 2025, validating additive manufacturing's role in rapid iteration cycles.

Product Spotlights

Aerojet Rocketdyne - GAMMA-H Scramjet Prototype

· Value: US$ 22 million program award

· Purpose: Reduce scramjet part count and cycle time using additive manufacturing

· Outcome: Expected to increase yield and accelerate rate production for hypersonic propulsion

Hermeus - Chimera Engine and Quarterhorse Mk 1

· First flight: May 27, 2025

· Uses Velo3D Sapphire printers for Inconel 718 engine and airframe components

· Significance: Demonstrates TBCC technology for reusable hypersonic aircraft

Ursa Major Technologies - Engine

· Thrust: 4,000 lbf storable engine for hypersonic and orbital maneuvering

· Progress: Over 50 hot-fire tests, with engines more than 80% 3D-printed by mass

· Contracts: AFRL award and Stratolaunch deal for 16 Hadley engines

Velo3D - Sapphire XC Platform

· Build size: 600 mm diameter × 550-1000 mm height

· Laser system: Eight 1 kW lasers enabling higher throughput

· Application: Used by Hermeus for flight-critical engine and airframe parts

Renishaw - RenAM 500Q/500D Series

· Specifications: Up to 4 lasers × 500 W, build area 250×250×350 mm

· Performance: Layer-time reduction up to 9 seconds per layer with TEMPUSTM technology

· Use case: Applied in aerospace and hypersonic R&D for precision thin-wall, high-temperature components

Sintavia - GRCop-42 Heat Exchangers

· Benefit: Up to 40% weight reduction and fivefold improvement in yield

· Technology: Specializes in large thermodynamic components for hypersonic propulsion

· 2025 milestone: First in North America to deploy dual 1.2 kW beam-shaping laser AM system

Verified Downstream Users

Lockheed Martin
Raytheon
Northrop Grumman
Boeing
Stratolaunch
Hermeus
Hypersonix Launch Systems
Kratos Defense & Security Solutions
Aerojet Rocketdyne
GKN Aerospace
MBDA
BAE Systems
Rocket Lab
Elementum 3D
ADDMAN

Market Trend

Integrated AM Propulsion Manufacturing

Defense programs are transitioning from part-level to engine-level additive manufacturing. Initiatives like GAMMA-H are consolidating production steps, cutting costs, and reducing supply-chain complexity. This integrated approach is becoming a baseline requirement for hypersonic propulsion.

Reusability and Test Cadence

The validation of recoverable hypersonic test vehicles has created a need for rapid redesign, production, and repair cycles. Additive manufacturing enables shorter development timelines and more frequent testing, ensuring sustained momentum in technology validation.

Breakthroughs in Materials

Advances in refractory metals and ceramics are redefining performance boundaries. 3D-printed niobium alloys and dark ceramics allow for operation under extreme thermal stress, paving the way for reliable leading edges, combustors, and propulsion chambers.

Hardware Scaling and Multi-Laser Platforms

Large-format metal 3D printers with multi-laser systems, such as Velo3D's Sapphire XC and Renishaw's RenAM 500Q, are now capable of building full-scale flight components. This hardware scaling ensures higher throughput while maintaining precision.

On-shoring and Policy Influence

National defense strategies prioritize secure supply chains, pushing for domestic additive manufacturing capacity. The fact that some engines are now 80% 3D-printed by mass underscores how additive manufacturing has shifted from an R&D tool to a production mainstay.

Academic-Industry Collaboration

Universities are embedding machine learning with additive manufacturing, improving first-pass yields and qualification standards. This fusion of AI and materials science is expected to become a core driver of hypersonic innovation by the late 2020s.

Flight Programs Driving Adoption

Flight milestones by Hermeus and Stratolaunch highlight the transition of 3D-printed parts from laboratory to operational environments. The increasing frequency of hypersonic test flights directly translates into sustained demand for AM-driven propulsion and thermal management solutions.

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