Italian firm establishes presence to support US defence needs

Italy's Avio, the leading manufacturer of rocket and missile motors, is poised to significantly increase its production capacity in the coming years, addressing a critical shortfall in the US defense industry.

The company’s CEO announced that in July, Avio signed an agreement with Raytheon to develop essential solid rocket motors for defense uses and has also partnered with the US Army to create and rapidly prototype a solid rocket motor for surface-to-air systems, Caliber.Az reports via foreign media.  

The rising demand for Avio’s products and expertise in the US stems from global conflicts and a reduced number of suppliers following Northrop Grumman's acquisition of Orbital ATK in 2018. While Avio is looking to establish a production facility in the US, it will initially manage its new American contracts from its Colleferro site in Italy.

“Currently, we produce 200 to 300 rocket motors annually at our Colleferro facility, and we can triple that output in 4 to 5 years based on existing commitments,” Avio CEO Giulio Ranzo stated in an interview with Defense News.   Avio is involved in the propulsion and various components for the Aster 30 missile, as well as the solid-propellant rocket motor for the new CAMM-ER air defense missile.

While the company’s primary focus is on space, having successfully launched 120 satellites over the past 12 years with 24 launches of its Vega launcher. Ranzo noted that it would take about two more years for Avio to qualify its Solid Rocket Motor (SRM) products at the Colleferro site to meet the requirements of recent US contracts. This method would be quicker and more reliable than waiting for the new US facility to complete its qualification process before starting large-scale production.

“US officials have indicated that domestic production would be ideal, but they recognize that it takes time. Building new capacity cannot be accomplished in just a few months,” he stated.   “There are many startups looking to enter this market, but achieving this requires decades of experience in large-scale production and a significant, authorized facility to manage explosives,” he added.   While details about the two US contracts remain limited, Ranzo noted, “We have recently worked on the new CAMM-ER missile, which provides us with up-to-date technical expertise. Most similar systems in the US date back to the 1980s.”  

Avio established a U.S. subsidiary, Avio USA, in 2022 and appointed James Syring, a retired US Navy vice admiral and former director of the US Missile Defense Agency, as its CEO. Syring stated to Defense News, “The consolidation of the industrial base has essentially left Northrop Grumman and Aerojet as the only manufacturers of solid rocket motors (SRMs), but even prior to this, there has been a persistent shortfall in rocket motor and missile production compared to current demand.”  

He continued, “This issue isn't new. When you speak to customers and prime contractors, they express that they would order double if they could. Ongoing conflicts have worsened the situation.”   Syring emphasized that the company's expansion is intended to enhance US production capacity rather than simply capturing market share. “We hear 'Buy American' frequently, which is why we are working to establish a significant factory presence in the US to serve all customers,” he explained.  

He also noted that the Department of Defense (DoD) has recognized the necessity of utilizing international production capabilities due to the overwhelmed supply base, and has been supportive of Avio’s establishment efforts.   In addition to expanding capacity, Syring highlighted Avio's innovative technologies. “Avio offers advanced technology and capabilities for booster cases, thermal protections, and nozzle manufacturing that no other US rocket motor supplier possesses.”

By Naila Huseynova