Aerospace firm Velontra is leveraging metal additive manufacturing (AM) technology to support hypersonic propulsion development. Their choice of laser powder bed fusion (L-PBF) for rapid prototyping is an AM method that requires post-processing technologies — hot isostatic pressing (HIP) being key to bring these types of AM parts to their full potential.
The original source was published in Metal AM, and the following content has been adapted for our Heat Treat Today audience.
Aerospace firm Velontra is using metal additive manufacturing (AM) technology to advance hypersonic engine development, signaling continued momentum in high-performance propulsion and downstream demand for post-processing capabilities.
Velontra, a Cincinnati, Ohio-based startup, partnered with Innovative 3D Manufacturing, a rapid prototyping company in Franklin, Indiana, to produce propulsion system components using laser power bed fusion (L-PBF) technology from Renishaw. The approach enables rapid prototyping while addressing material use, dimensional tolerances, and cost constraints.
CTO
Velontra
“Compact hypersonic propulsion systems are highly sought after by space companies, so, to remain competitive, we must develop parts quickly,” explained Joel Darin, CTO of Velontra. “In aerospace, we know that the best way to learn is by doing things, particularly if you want to be the first to launch a new technology.”
While the focus is on AM production, the resulting components require post-processing to achieve final material properties. Parts produced via L-PBF are typically subjected to stress relief and heat treatment to stabilize microstructures formed during rapid solidification. For high-temperature aerospace alloys, hot isostatic pressing (HIP) may also be applied to reduce internal porosity and improve structural integrity.
This requirement is consistent with broader industry findings for nickel-based superalloys used in propulsion systems. As noted in Dan Herring and Nikolai Alexander’s article published in Heat Treat Today’s Annual Aerospace Heat Treating magazine (March 2026) covering IN 718 processing, powder bed fusion methods often rely on post-HIP to heal cracks and homogenize the microstructure.
As adoption of AM expands in aerospace applications, supporting technologies such as heat treating and HIP are expected to scale alongside it. Industry perspectives highlighted in Heat Treat Today’s Medical & Energy Heat Treat magazine (December 2025) indicate that HIP capabilities are evolving in response to increased demand from additive manufacturing and advanced materials development.
The integration of AM with post-processing underscores the role of heat treating in enabling next-generation propulsion systems, where component performance under extreme conditions remains a key requirement.
Press release is available in its original form here.
Main image shows the additively manufactured afterburner casing for the hypersonic propulsion system with several components combined into one part. | Image Credit: Renishaw
