Vaya Space

Vaya Space (formerly Rocket Crafters), founded in 2010 and headquartered in Cocoa, Florida, develops hybrid rocket propulsion technology using a proprietary STAR-3D (Spinning Toroidal Architecture with Rotating 3D printed fuel) vortex combustion approach — where the LOX (liquid oxygen) oxidizer flows in a spiral pattern through a 3D-printed thermoplastic solid fuel grain, creating a vortex that dramatically improves hybrid engine combustion efficiency versus conventional end-burning hybrid designs.

Conventional hybrid rockets (LOX/HTPB or N2O/PE) suffer from low regression rates that limit thrust-to-mass ratio — the fuel grain burns slowly because oxidizer transport to the burning surface is diffusion-limited. Vaya Space's STAR-3D architecture uses rotating vortex oxidizer flow that continuously scrubs the burning fuel surface, increasing oxidizer mass flux and fuel regression rate to achieve combustion efficiencies comparable to liquid-propellant engines. The fuel grain is 3D-printed from thermoplastic polymers — 99% recycled content per company claims — creating complex internal channel geometry that is impractical with conventional cast HTPB fuels but enabled by additive manufacturing.

The STAR-3D engine produces 110 kN thrust and is the propulsion basis for Vaya Space's Dauntless orbital launch vehicle targeting 600+ kg payload to sun-synchronous orbit — a competitive specification in the small launch vehicle market segment between RocketLab Electron (300 kg) and SpaceX Transporter rideshare. Vaya Space has an allocated Cape Canaveral launch pad assignment at SLC-46, providing launch infrastructure without requiring the company to build its own facilities.

In 2025, Vaya partnered with Velo3D, an industrial metal additive manufacturing company, through a $4 million collaboration targeting advanced 3D-printed metal components for Dauntless propulsion systems. The company competes with ABL Space Systems, Relativity Space, and Rocket Lab in the small dedicated orbital launch market.