Aurora Labs (A3D ASX) has taken a step forward in its Defence contract with the Australian Department of Defence, announcing completion of the critical “design freeze” phase for a novel, 3D-printed propulsion engine.
Under the Defence innovation contract awarded in December 2024, the company has finalised engineering for a next-generation micro gas turbine engine.
The system uses Aurora’s proprietary Laser Powder Bed Fusion (LPBF) technology. With hardware now entering production, Aurora is moving into the testing and validation stage—on schedule.
“This is a major technical and strategic achievement,” said CEO Rebekah Letheby. “Our ability to print complex geometries with up to 99.8% density highlights the readiness of our technology to support sovereign Defence manufacturing.”
A Step Towards Sovereign Aerospace Manufacturing
The propulsion system is designed for unmanned aerial systems (UAS) and defence applications. It supports Australia’s Guided Weapons and Explosive Ordnance (GWEO) Plan and complements AUKUS Pillar 2 goals, including the development of hypersonic and autonomous capabilities.
The completed design phase included final engine engineering, setup of a sensor-equipped test cell, and procurement of long-lead manufacturing items. Aurora has also achieved early success in manufacturing trials, printing high-density, mission-critical parts using Ti-5 materials.
This marks a significant advancement in Australia’s ability to manufacture complex aerospace components locally—many of which are not currently produced domestically.
Next Phase: Fabrication and Testing
With the design freeze milestone met, Aurora will now begin full-scale fabrication and ground testing. These activities are part of Milestones 2 and 3 in the ADF contract.
Aurora retains full intellectual property and commercialisation rights to the propulsion system. This strengthens its position as a key player in advanced manufacturing and Defence innovation.
More can be read at the A3D website here.
