X-Bow Systems to Build Boosters for CHAOS Missile Program

The manufacturer will apply additive production methods to support the Navy’s low-cost cruise missile initiative.

Updated on Oct. 27, 2026 in Semiconductors

Isometric editorial illustration of a cylindrical rocket motor component with exposed internal propellant structure, reflecting advanced manufacturing. — X-Bow Systems will manufacture solid rocket boosters for the U.S. Navy’s CHAOS cruise missile program, utilizing additive manufacturing to scale production. AI Illustration. Upload story photo >

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X-Bow Systems will develop solid rocket boosters for the CoAspire CHAOS cruise missile program. This follows a $70 million prototype agreement the U.S. Navy awarded to CoAspire in July 2026.

Why it matters

The CHAOS program is intended to provide allied nations with a cost-effective weapon for targeting land and maritime assets. The project relies on additive manufacturing to scale the production of rocket motors for the missile.

The CHAOS missile is designed for a maximum strike range of 1,000 nautical miles, significantly exceeding the 140-nautical-mile requirement. X-Bow will manufacture these motors using additive manufacturing at its Luling, Texas facility, which has an annual production capacity of 500 motors.

The players

X-Bow Systems

An aerospace company based in Albuquerque, New Mexico, that specializes in additive manufacturing for solid rocket motor production.

CoAspire

A Virginia-based defense firm leading the development of the CHAOS cruise missile program under U.S. Navy oversight.

U.S. Navy

The branch of the U.S. Armed Forces overseeing the development and international procurement of the CHAOS cruise missile system.

The details

A solid rocket motor functions as a booster that provides the initial thrust to accelerate a cruise missile to operating speeds. Once the booster completes its burn, the system jettisons the casing, allowing the cruise missile's onboard wings and jet engine to take over for sustained flight. X-Bow uses additive manufacturing, a process that builds objects layer-by-layer from 3D data, to construct these solid propellant motors, aiming to streamline production cycles.

Late 2025: X-Bow opened its production site in Luling, Texas.
July 17, 2026: The U.S. Navy awarded CoAspire a $70 million prototype agreement.
September 2026: The U.S. Navy awarded Zone 5 Technologies $65 million for a maritime strike missile.
October 7, 2026: The U.S. Navy awarded X-Bow a $69.7 million booster development agreement.
October 27, 2026: X-Bow announced its role as the booster contractor for the CHAOS program.

The Tech Race

The CHAOS program is designed to create a low-cost, high-performance weapon that the U.S. Navy intends to distribute via the Foreign Military Sales program. This development follows a pattern of prioritizing scalable manufacturing, as seen in the simultaneous $65 million contract awarded to Zone 5 Technologies.

The program is currently in the prototype stage, meaning it is not yet deployed for operational use. Allies of the United States are the primary target population for this technology as the program aims to offer these cruise missiles for purchase through official government channels.

The takeaway

The CHAOS program demonstrates a clear shift toward using additive manufacturing for rapid, scalable missile production in the U.S. defense sector. Readers should track upcoming test flight results for the CHAOS platform to confirm if the 1,000 nautical mile range projections are met in operational conditions.