HUNTSVILLE, Ala.—Aerobotix, a leading robotic integrator for the aerospace and defense industries, today unveiled a fully operational robotic hypersonic missile production line. The advanced system enables defense contractors to reduce material costs and enhance manufacturing capabilities while introducing automation technology to hypersonic missile production.

Earlier this year, the Pentagon directed prime contractors to reduce hypersonic missile costs, citing concerns about program affordability. In response, Aerobotix has demonstrated expertise in robotically applying Minteq’s FIREX RX-2390, an ablative thermal protection coating engineered to withstand extreme hypersonic flight temperatures. The company identifies this as a strategic opportunity for prime manufacturers to achieve significant cost reductions through automation.

“We initiated small-scale panel testing of RX-2390 earlier this year for a key customer,” said Josh Tuttle, business development manager at Aerobotix. “Throughout this process, we collaborated closely with Minteq and achieved successful results with their material. Currently, we are negotiating a distribution agreement. This partnership addresses a critical industry challenge, as several hypersonic missile manufacturers face difficulties sourcing an appropriate thermal protection system and securing the specialized workforce required for its application.”

The production line integrates six industrial robots and a curing booth to scan, sand, paint and measure complex missile components. The system delivers the precise tolerances essential for hypersonic flight performance. Given the extreme operating conditions of hypersonic missiles, both thermal protection integrity and aerodynamic consistency are mission-critical.

“The process begins with an automated Shape Fidelity Scanner that captures each component’s as-built dimensional data,” explains Kent Pfeifer, process engineering manager at Aerobotix. “This data generates customized tool paths to scuff sand each component, ensuring optimal coating adhesion. An explosion-proof paint robot subsequently applies multiple layers of MINTEQ’s FIREX RX-2390 ablative coating. To verify coating thickness remains within specification, the robot employs a non-contact measurement system to record wet coating thickness in real-time.”

Aerobotix’s objective is to support defense contractors with low-volume production runs and research and development initiatives. As a result, this capability provides critical manufacturing capacity as contractors retrofit existing facilities or construct new production infrastructure.