Albany Engineered Composites has invested more than $36 million in manufacturing capabilities for hypersonic vehicles, solid rocket motors, and space systems, as the company expands production infrastructure for advanced high-temperature materials.
The company announced the expansion through AEC Advanced Programs (AEC-AP), a wholly owned subsidiary established in 2021. Its approximately 70,000-square-foot facility in Rochester, New Hampshire, is designed to support the production of advanced composite hardware for extreme operating environments.
The investment is complemented by a $21.2 million US government contract awarded in September under the Industrial Base Analysis and Sustainment (IBAS) program. The 30-month contract will support development of carbon-carbon composite thermal protection systems for hypersonic vehicles and solid rocket motors.
Thermally protected facilities
Hypersonic vehicles and solid rocket motors operate under demanding thermal conditions, requiring materials and structures that can withstand intense heat. Carbon-carbon composites are designed for high-temperature applications and can be used in thermal protection systems that help shield critical hardware.
Albany said its new facility will support vertically integrated manufacturing, bringing multiple stages of production and development together. Its capabilities are intended to cover advanced composite thermal protection systems and other hardware for hypersonic, rocket motor, and space applications.
The Rochester facility includes dedicated equipment for full-scale hardware production. Planned additions in densification, machining, and inspection are expected to expand its capabilities as customer requirements and production volumes grow.
The company is also leveraging its near-net-shape 3D-woven composite technology, along with design and simulation capabilities. Near-net-shape manufacturing aims to produce components close to their final dimensions, potentially reducing the amount of material removal and additional processing required.
According to Albany, these capabilities could help move advanced composite designs from development into scalable manufacturing.
Scaling hypersonic composites
The expansion comes alongside a broader push to strengthen the US industrial base for hypersonic systems. The $21.2 million IBAS award will support carbon-carbon composite thermal protection systems for hypersonic vehicles and solid rocket motors.
Albany has also announced a teaming agreement with Lockheed Martin to pursue scalable production of next-generation US hypersonic systems, including hypersonic glide body applications.
Hypersonic weapons travel at speeds above Mach 5, creating demanding thermal and engineering requirements. For glide vehicles in particular, thermal protection is important because aerodynamic heating can expose vehicle surfaces to extreme temperatures during flight.
Manufacturing capacity is another challenge. Advanced composites can require specialized equipment, carefully controlled processes, and extensive inspection. Dedicated facilities could help suppliers prepare for higher production volumes as programs move beyond research and development.
Chris Stone, president of Albany Engineered Composites, said the combination of existing investments, the IBAS contract and the Lockheed Martin collaboration would help provide scalable high-temperature composite capabilities for customers and the US industrial base.
From advanced materials to production
AEC-AP was established to develop carbon-carbon manufacturing capabilities for high-temperature, extreme-environment applications. Its Rochester location sits adjacent to Albany Engineered Composites’ headquarters and research and development operations.
The company said the facility is designed to expand as program requirements evolve. Its planned capabilities suggest an emphasis not only on developing advanced materials but also on manufacturing and inspecting finished components at production scale.
As the US advances hypersonic weapons and other high-temperature aerospace systems, the ability to manufacture specialized thermal protection components at scale will remain an important part of turning designs into deployable hardware.