Additive Manufacturing in Aerospace: Momentus and Velo3D's Fuel Tank Innovation and Its Implications for Space Industry Disruption

The aerospace industry is undergoing a quiet revolution, driven by additive manufacturing (AM) technologies that promise to redefine the economics and capabilities of space exploration. At the forefront of this shift is the collaboration between Momentus Inc. and Velo3D, whose development of an additive manufactured fuel tank for the Vigoride-7 Orbital Service Vehicle exemplifies how strategic partnerships are catalyzing scalable space tech investment. This innovation, coupled with broader industry trends, underscores the transformative potential of AM in aerospace and highlights the critical role of alliances in accelerating adoption.

The Momentus-Velo3D Partnership: A Case Study in AM-Driven Innovation

Momentus and Velo3D's five-year, $15 million master services agreement represents more than a procurement deal-it is a strategic alignment of expertise to push the boundaries of spacecraft design. By leveraging Velo3D's Sapphire XC 3D metal printers, Momentus is producing fuel tanks with optimized geometries that reduce weight while maintaining structural integrity, a critical factor for in-space missions according to reports. These tanks, set for flight testing in 2025, are not just components but enablers of a new paradigm: spacecraft that are lighter, faster to produce, and more cost-effective.

The partnership's significance extends beyond technical achievement. Momentus plans to commercialize these 3D-printed components for third-party customers, creating a revenue stream that bridges the gap between R&D and mass production. This dual-use strategy-serving internal needs while addressing external demand-reflects a scalable business model that investors should note. As aerospace firms increasingly prioritize agility and cost efficiency, the ability to rapidly iterate and produce mission-critical parts through AM becomes a competitive advantage.

Broader Industry Trends: AM as a Catalyst for Disruption

The Momentus-Velo3D collaboration is part of a larger wave of AM adoption in aerospace. In 2025, the aerospace additive manufacturing market is projected to grow at a compound annual growth rate (CAGR) of 18.3%, reaching $3.8 billion by 2030. This surge is fueled by the technology's ability to produce lightweight, high-performance parts that traditional methods cannot replicate. For instance, Airbus is integrating AM into its sustainability strategy, using 3D printing to create lighter components that reduce emissions. Similarly, 3D Systems' aerospace and defense business is forecasted to grow over 15% in 2025, driven by U.S. government support for domestic supply chains.

Strategic partnerships are accelerating this transition. SpaceX's $8 million agreement with Velo3D and Relativity Space's use of 3D printing to manufacture entire rockets illustrate how AM is moving from prototyping to full-scale production. These collaborations are not isolated; they are part of a systemic shift toward on-demand manufacturing, which mitigates supply chain risks and reduces lead times-a critical factor in an industry where delays are costly according to industry analysts.

Investment Implications: Strategic Alliances as a Proxy for Resilience

For investors, the rise of AM in aerospace signals an opportunity to back companies that are not only innovating but also forming robust partnerships. The Momentus-Velo3D model-where a space systems provider teams with a specialized AM firm-demonstrates how cross-industry alliances can de-risk development and scale production. This is particularly relevant in an era where regulatory hurdles and material limitations still constrain AM adoption. By pooling resources and expertise, partners like Momentus and Velo3D can navigate these challenges more effectively than solo operators.

Moreover, AM's alignment with sustainability goals adds another layer of appeal. As governments and corporations prioritize carbon reduction, the ability to produce parts with minimal waste and localized manufacturing becomes a strategic asset. For example, GKN Aerospace's expansion of additive manufacturing capabilities in Norway, supported by a $1.25 million co-investment, highlights how AM is being integrated into global supply chains to meet both performance and environmental benchmarks.

The Road Ahead: Challenges and Opportunities

Despite its promise, AM faces hurdles, including certification complexities and material constraints according to market analysis. However, industry-wide efforts-such as the America Makes Institute's focus on defense-related AM priorities and Honeywell's AI-driven production innovations-are addressing these barriers. Investors should monitor companies that are not only adopting AM but also contributing to the development of industry standards and certification frameworks, as these will be pivotal in scaling the technology.

The 3D-printed rockets market, projected to grow at a CAGR of 10.9% from 2025 to 2033, further underscores the long-term potential of AM. Firms like Relativity Space and SpaceX are proving that 3D printing can revolutionize launch systems, reducing costs and enabling rapid iteration. For investors, this suggests that early-stage bets on AM-capable aerospace firms could yield outsized returns as the technology matures.

Conclusion

The collaboration between Momentus and Velo3D is more than a technical milestone-it is a blueprint for how strategic partnerships can drive scalable innovation in aerospace. By combining AM's design flexibility with the agility of cross-industry alliances, companies are not only overcoming traditional manufacturing limitations but also redefining the economics of space exploration. For investors, the lesson is clear: the future of aerospace lies in ecosystems that prioritize collaboration, adaptability, and technological convergence. As AM transitions from niche to mainstream, those who align with pioneers like Momentus and Velo3D will be well-positioned to capitalize on the next frontier of space industry disruption.