Astrobase Unveils India’s First 80-Tonne FFSC Methalox Engine
The Bengaluru-based startup is using industrial 3D printing to develop a high-efficiency propulsion system for heavy-lift rockets.
Bengaluru-based Astrobase Space Technologies has unveiled India’s first fully integrated 80-tonne-class Full-Flow Staged Combustion (FFSC) rocket engine. The development marks a critical pivot toward high-performance, indigenous propulsion for the nation's private space sector.
The new engine delivers 800 kN of thrust and is powered by a combination of liquid oxygen (LOX) and methane, known as methalox. According to the company, the entire system was conceptualized and manufactured in-house in India. To achieve this, Astrobase utilized industrial metal 3D printing, which Co-founder Neeraj Khandelwal stated was used to streamline complex geometries and reduce production bottlenecks.
The Complexity of FFSC
Full-Flow Staged Combustion is regarded as one of the most efficient yet complex rocket engine cycles. By routing all propellant through the pre-burners before they enter the main combustion chamber, the system maximizes performance and reliability. While the Soviet Union first tested an FFSC engine (the RD-270) between 1967 and 1969, the architecture has recently gained global prominence through SpaceX’s Raptor engines. Astrobase is accelerating the development of its own 800 kN version by leveraging the Indian government's IN-SPACe Technology Adoption Fund (TAF).
Strategic Implications
This milestone signals a shift in India's aerospace capabilities, moving beyond basic rocket designs toward the heavy-lift and potentially reusable architectures required for deep-space exploration. By mastering the FFSC cycle and integrating additive manufacturing, Astrobase is positioning India to compete with global leaders in deep-tech engineering. This indigenous approach reduces the strategic reliance on foreign propulsion technology and lowers the cost of accessing space for commercial and government payloads.
Path to Flight
Astrobase has already begun validating the hardware, having successfully completed a sub-scale hot fire test in September 2025. The company operates a 21.5-acre test facility in Andhra Pradesh, featuring a test stand capable of handling 200 tons (2,000 kN) of upward thrust, providing ample headroom for the 80-tonne engine's requirements. While the company is now moving toward full-scale ground hot-fire tests, industry reports from idrw.org indicate that Astrobase is targeting a full vehicle flight test by 2028.