In the rapidly evolving landscape of manufacturing, innovative startups are continuously striving to redefine the capabilities and efficiencies of production processes. Raven Space Systems, a Kansas City-based startup, has emerged as a frontrunner by developing a groundbreaking method for scaling the 3D printing of thermoset composites, a material favored for its lightweight yet durable characteristics primarily in aerospace and defense applications. This advancement represents a significant leap toward solving long-standing challenges associated with the high costs and extensive lead times typically associated with these materials.
The startup has introduced a process known as Microwave Assisted Deposition (MAD) 3D printing. This innovative technique allows thermoset composites to be cured during the printing process itself, significantly reducing time constraints that traditionally required hours or even days in an oven. According to Raven’s co-founder and CEO, Blake Herren, this technology unlocks an entirely new field of 3D printing at production scale, enabling the automation of near net shape production.
Herren and his colleague, Ryan Cowdrey, conceived the MAD technology during their time as graduate students at the University of Oklahoma. Following their graduation, they secured approximately one million dollars in grants through the Small Business Innovation and Research program, facilitating the transition of their concept from theory to working prototype. Since 2020, Raven has garnered around $4.5 million in non-dilutive contracts from prestigious entities including the Air Force, NASA, and the National Science Foundation.
Recently, Raven closed a $2 million pre-seed funding round, primarily led by Backswing Ventures, with contributions from other investors such as 46 Venture Capital and Mana Ventures. The fresh capital infusion is aimed at setting up the company’s first full-scale manufacturing lines, which will include producing advanced 3D printers, mixing systems, and machining facilities. By mid-2025, Raven plans to relocate from its current 3,000-square-foot workspace to a larger factory certified for aerospace production, where it will begin fabricating components tailored to customer specifications.
The initial focus of Raven’s go-to-market strategy lies in providing thermal protection components for solid rocket motors and hypersonic vessels. Herren emphasized that current geopolitical dynamics necessitate resilient supply chains and innovations to meet the demands of the Department of Defense (DoD), which has recognized significant supply challenges within these sectors. “There’s a massive need there—supply chain bottlenecks are causing urgent problems for companies requiring thermal protection and structural materials,” he noted.
Despite the existing suppliers in the market, Herren highlighted the inadequacies of many factories that still rely on outdated manufacturing techniques, emphasizing a pressing need for modernization. He stressed that optimizing the MAD printing process will coincide with the construction of their state-of-the-art manufacturing facility, which aims to drastically reduce lead times from several months to just a few days.
Innovations in manufacturing processes and technologies are crucial as industries push to compete on a global scale. Beyond applications within aerospace and defense, Raven Space Systems has also engaged in discussions with various players in the autonomous systems and satellite manufacturing sectors, revealing the broad potential impact of their technology.
Notably, Raven has partnered with SpaceWorks, an established developer of reentry capsules, to pioneer the fabrication of 3D-printed aeroshells. These structures are integral to protecting spacecraft during reentry into the earth’s atmosphere and will facilitate the DoD’s exploration of hypersonic technologies.
While the technology is still in its early phases, Herren acknowledges existing challenges related to scaling the production of larger structures but remains optimistic about its future. He envisions that once fully optimized, this manufacturing approach will fundamentally alter the way large-scale composites are produced and utilized.
As Raven Space Systems accelerates toward its ambitious goals, the implications of its innovations extend well beyond the immediate benefits of reduced production times and costs. They provide a glimpse into the future of manufacturing—one where efficiency, adaptability, and advanced materials technology converge to meet the evolving demands of various industries.
Raven’s commitment to developing the most efficient production lines will undoubtedly enhance their capabilities in addressing the significant supply chain issues that experts and industries across the globe are grappling with. With continued investments and focus on innovation, the future looks promising not just for Raven Space Systems, but for the industrial 3D printing landscape as a whole.