Firefly Aerospace has secured a new contract from the Air Force Research Laboratory (AFRL) to develop a cutting-edge ceramic matrix composite (CMC) nozzle extension for liquid rocket engines. The contract marks a significant step in advancing next-generation rocket technology aimed at improving performance and reducing costs.
In pic- Firefly’s Miranda engine: A scaled-up evolution of Reaver’s tap-off cycle, with upgraded turbopumps, fluid systems, and valves—boosting thrust 5X while maintaining flight-proven reliability. Credit: Firefly Aerospace
The CMC nozzle extension will be developed at AFRL's facility at Edwards Air Force Base in California and is designed to enhance rocket efficiency by reducing weight and increasing payload capacity. Compared to conventional metal-based nozzle extensions, Firefly’s CMC technology promises substantial benefits, including lower production costs and improved thermal resistance.
“Firefly’s deep experience in both carbon composites and rocket propulsion uniquely positions us to lead this development,” said Jason Kim, CEO of Firefly Aerospace. “By integrating lightweight composite materials into our launch vehicles, we can significantly cut mass and increase the payload our rockets can carry—delivering greater value to our customers.”
Traditionally, nozzle extensions have relied on heavy and costly metal alloys, often sourced from international suppliers. Firefly’s CMC alternative offers over a 50% reduction in mass while maintaining high strength and heat resistance. Additionally, the use of domestically sourced materials and an efficient spin-forming production technique can reduce lead times from months to weeks.
The new nozzle extension is intended to support responsive space missions for U.S. national security as well as broader commercial space initiatives. Once validated, the technology will be incorporated into Firefly’s Lightning and Vira second-stage engines, which power the Alpha and Medium Launch Vehicle platforms.
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