Serrano rocket engine is 3D-printed: Leap Space unveils engine for Bighorn launcher

Leap Space has unveiled the Serrano rocket engine, built largely through metal 3D printing. The unit is designed for the upcoming Bighorn launch vehicle, which targets small satellite missions.

The key feature of Serrano is not individual parts but large complex assemblies printed as single pieces. This approach eliminates hundreds of joints and cuts the number of manufacturing steps, speeding up engine production. Engineers also gain more design freedom: Serrano can include cooling channels and elements that would be impossible to make with traditional methods. Component geometry is optimized for flow, pressure, and heat transfer.

Leap Space expects additive manufacturing to reduce engine weight, boost efficiency, and simplify future upgrades. When the design changes, there is no need to retool production lines — a new version can be sent to print faster. This matters especially for the small-satellite launch market, where cost and production ramp-up speed are critical.

The main test for Serrano will be fire tests, followed by actual Bighorn launches. Only then will it be clear whether Leap Space can deliver on its promise of low cost, reliability, efficiency, and fast manufacturing.