This week, I had the opportunity to take a tour of rocket engine maker Ursa Major‘s headquarters in Berthoud, Colorado, lead by their CEO Joe Laurienti. Thanks to Joe and the rest of the team for the in-depth discussion of Ursa Major’s technology, outlook on the industry and future of humanity in space, and emerging business opportunites. Although I wasn’t allowed to take photos or video, here’s a quick rundown of a few of the key topics we covered during the tour:
Key Discussion Topics:
- Facility Overview and History:
- The site, initially designed for environmental testing by Ball Aerospace, has undergone several transformations, including a period where it was used for munitions manufacturing. Ursa Major acquired it, repurposing it into a cutting-edge rocket engine production facility.
- Engine Production and Capabilities:
- The tour showcased the production lines for Hadley, Ripley, and Draper engines. Highlights included the 3D printing of major engine components using proprietary alloys, allowing for unprecedented design flexibility and performance optimization. The Ripley engine, notable for its high-pressure kerosene fuel system, represents a significant advancement in American rocket technology.
- Innovative Manufacturing Techniques:
- A substantial focus was on the use of 3D printing for engine parts, including the complex geometries and high-performance materials like Inconel and copper alloys. This approach significantly reduces part count and assembly time compared to traditional methods.
- Testing and Iteration:
- Ursa Major’s approach emphasizes rapid prototyping and testing, with a facility capable of supporting extensive test campaigns. The integrated testing and manufacturing capabilities allow for quick iterations, vital for the development of cutting-edge technologies like hypersonic engines.
- Future Developments and Applications:
- The discussion covered potential applications for their engines in both space and hypersonic domains, driven by interest from the U.S. Air Force and the Space Force. The Draper engine, designed for tactical responsiveness, highlights Ursa Major’s focus on meeting defense needs while pushing the boundaries of propulsion technology.
Overall, the tour highlighted Ursa Major’s innovative approach to rocket engine development, from advanced materials and 3D printing to integrated testing and rapid iteration, positioning the company at the forefront of aerospace propulsion technology.
For a great in-depth look at Ursa Major’s Berthoud HQ, check out Tim Dodd’s excellent tour video: