How Aurora Labs Is Powering Australia’s Next-Gen Defence Tech

Redefining Sovereign Manufacturing

Aurora Labs, an Australian advanced manufacturing company, is carving out a significant role in the defence and aerospace sectors through its proprietary Laser Powder Bed Fusion (LPBF) 3D printing technology. With over a decade of expertise, Aurora delivers high-performance metal components that are lighter, stronger, and more complex than those produced by traditional manufacturing methods. This capability is particularly critical for defence applications where precision, durability, and rapid deployment are paramount.

The company’s technology not only reduces material waste but also accelerates the design-to-deployment timeline, a crucial advantage in the fast-evolving landscape of modern warfare. Aurora’s solutions are already trusted by the Australian Defence Force (ADF) and supported under the AUKUS alliance, underscoring its strategic importance in sovereign manufacturing.

Contract Wins and Strategic Partnerships

Since mid-2024, Aurora Labs has secured five contracts with the ADF totaling approximately A$914,200. These include orders for experimental metal alloy 3D printed parts and a significant contract worth $319,000 to design and manufacture an advanced propulsion system. This milestone contract not only validates Aurora’s technology but also establishes a commercial pathway that substantially de-risks its propulsion system development.

Further cementing its position, Aurora entered a strategic partnership with Sovereign Propulsion Systems (SPS), a specialist Australian defence aerospace company. SPS will integrate Aurora’s next-generation propulsion systems into its unmanned aerial systems (UAS) platforms and conduct rigorous bench and aerial testing at its state-of-the-art facilities. This collaboration is pivotal for Aurora’s commercialisation ambitions, with SPS also acting as a distributor to AUKUS partner countries.

Innovating Propulsion and Warhead Components

Aurora’s propulsion portfolio includes the AU2 and AU4 micro gas turbines, with the AU2 already commercially available and the AU4 undergoing certification testing to meet military specifications. The company is also contracted to develop a next-generation novel propulsion system, with prototype manufacturing and testing underway and expected to progress through 2026.

Beyond propulsion, Aurora manufactures complex warhead components using advanced alloys, leveraging its additive manufacturing expertise to improve performance and reduce costs. These capabilities align with the Australian Government’s strategic focus on strengthening sovereign manufacturing and supply chains for guided weapons and autonomous vehicles.

Market Context and Growth Outlook

Global defence spending reached a record US$2.7 trillion in 2024, driven by geopolitical tensions and evolving warfare dynamics, including the rapid development of unmanned aerial vehicles and drone warfare. Aurora is well positioned to capitalise on these trends, supported by Australia’s projected defence budget growth and initiatives like the Advanced Strategic Capabilities Accelerator (ASCA), which funds asymmetric military capabilities development.

Looking ahead, Aurora plans to scale production at its Western Australia facility, continue R&D to enhance its proprietary technologies, and expand partnerships with international defence primes. The company recently received a $500,000 defence grant to support production machinery upgrades, further underpinning its growth trajectory.

Leadership and Risk Management

Aurora’s experienced board and management team bring diverse expertise spanning aerospace engineering, defence consultancy, investment banking, and global commodities trading. This leadership is critical as the company navigates risks inherent in commercialising disruptive manufacturing technologies, including market acceptance, competition, reliance on key personnel, and supply chain challenges.

The company maintains ISO 9001 quality accreditation and is pursuing AS9100D certification to meet aerospace and defence industry standards, essential for expanding contract manufacturing services. Aurora also holds patents across multiple jurisdictions, protecting its innovative manufacturing processes.