L3Harris cuts hypersonic propulsion component build time tenfold

L3Harris Technologies, a US defense firm, has significantly advanced additive manufacturing for air-breathing hypersonic propulsion systems, achieving a tenfold reduction in component production time. This progress supports the GAMMA-H initiative, which aims to develop scalable, cost-effective manufacturing solutions for hypersonic propulsion. By leveraging large-envelope metal 3D printers and powdered metal feedstock, L3Harris can produce complex high-temperature components—such as scramjet engines made from nickel-based superalloys—with integrated cooling channels and lattice structures that are difficult to manufacture conventionally. The company employs robotic handling, autonomous build monitoring, and in-situ sensors to enhance print quality, reduce defects, and minimize post-processing. The streamlined process consolidates multiple subcomponents into single printed assemblies, cutting down part counts, fasteners, welds, and machining steps, thereby lowering costs and increasing production rates. This effort builds on L3Harris’s hypersonic heritage and is supported by a $22