Plasma Processes
Plasma Processes is a privately held Huntsville, Alabama-based specialty materials manufacturer founded in 1993 that develops advanced coatings, refractory metal components, and ASCENT green propellant thrusters for aerospace, defense, space, and energy customers including NASA, SpaceX, and major defense primes.
- Company typePrivate
- Founded1993
- HeadquartersHuntsville, United States
- Headcount11–50
- GTM typeB2B
- OfferingHardware or Manufacturing
What Plasma Processes does
Plasma Processes LLC is a privately held, AS9100D/ISO 9001:2015-certified specialty materials manufacturer founded in 1993 by Tim McKechnie in Huntsville, Alabama. The company develops and manufactures advanced coatings, refractory and platinum group metal components, and propulsion hardware for aerospace, defense, space, and energy applications, with in-house capabilities spanning Vacuum Plasma Spray, Atmospheric Plasma Spray, El-Form® molten salt electrodeposition, additive manufacturing, machining, and arc-jet testing. Its core technology is the proprietary El-Form® process, which produces >99% density refractory and platinum group metal structures and is protected by eight issued US patents; flight heritage includes the optical coating on NASA's Parker Solar Probe heat shield and thruster hardware aboard GPIM, Lunar Flashlight, and a growing installed base on orbit.
The company generates revenue through three primary streams: contract manufacturing and coating services (project-based long-term contracts with defense primes, government agencies, and aerospace contractors), materials development and testing services (custom powder formulation, metallurgical analysis, arc-jet testing), and hardware product sales — most notably ASCENT-based green propellant thrusters (0.1N to 110N) sold through its wholly-owned subsidiary Rubicon Space Systems. The go-to-market motion is enterprise direct sales via RFQ, with sales at 256-489-8708 and an IDIQ contract vehicle for Missile Defense Agency programs. The customer base spans Lockheed Martin, Northrop Grumman, RTX, L3Harris, SpaceX, Blue Origin, Aerojet Rocketdyne, Pratt & Whitney, Rolls Royce, NASA, DoD, DOE, and multiple national laboratories.
Following a facility expansion to 80,000 sq. ft. completed in July 2025, headcount growth to 80+ employees, an 8th patent issued in 2025, and a new 110N ASCENT thruster NASA contract, Plasma Processes is positioned as a vertically integrated, flight-qualified supplier in the domestic defense and space materials supply chain, with growing exposure to energy, medical, and semiconductor verticals.
Plasma Processes firmographics
Firmographics- Name
- Plasma Processes
- Legal name
- Plasma Processes LLC
- Website
- https://plasmapros.com
- Company type
- Private
- Founded year
- 1993
- Operating status
- Operating
- Headcount range
- 11–50 employees
- Short description
- Plasma Processes is a privately held Huntsville, Alabama-based specialty materials manufacturer founded in 1993 that develops advanced coatings, refractory metal components, and ASCENT green propellant thrusters for aerospace, defense, space, and energy customers including NASA, SpaceX, and major defense primes.
- Ownership category
- akta.pro rank
Plasma Processes industry classification
Industry- Product category
- Advanced Aerospace Materials and Coatings Manufacturing
- NAICS
- Guided Missile and Space Vehicle Propulsion Unit and Propulsion Unit Parts Manufacturing (336415), Other Guided Missile and Space Vehicle Parts and Auxiliary Equipment Manufacturing (336419), Aerospace Product and Parts Manufacturing (33641)
- SIC
- Guided Missiles & Space Vehicles & Parts (3760), Aircraft Engines & Engine Parts (3724)
- akta.pro primary industry
- Thermal Spray & Metallizing (HVOF/Plasma/Arc) (IMAIAKAF)
- akta.pro secondary industries
- Space Structures, Mechanisms & Thermal Control (IMABACAF), Spacecraft Propulsion (In-Space) & Thrusters (IMABACAE)
Keywords
Where Plasma Processes is headquartered
LocationHeadquarters
- HQ city
- Huntsville
- HQ country
- United States
- HQ region
- North America
Offices4 records
Markets served
Plasma Processes business model
Business model- GTM type
- B2B
- Offering type
- Hardware or Manufacturing
- Cost components
- Personnel, Operations, Technology or R&D, Supply Chain, Infrastructure, Marketing or Sales
Revenue model
- Contract Manufacturing Services: Plasma Processes generates revenue through contract manufacturing of specialized components and coatings for aerospace, defense, and space applications. Services include coating, additive manufacturing, machining, and assembly. Revenue is project-based with long-term contracts with defense primes and government agencies.
- Materials and Testing Services: Provides material testing services including arc-jet testing, metallurgical analysis, and powder processing. Revenue generated through R&D services, material development, and testing contracts.
- Propulsion Products (Rubicon Space Systems): Sales of ASCENT-based thrusters and propulsion systems through Rubicon Space Systems division. Includes 0.1N, 1N, 5N, and 110N thrusters for satellites and spacecraft.
Go-to-market motion1 record
Distribution channels2 records
Marketing channels4 records
Plasma Processes product offering
Product offeringCore offering
Plasma Processes manufactures advanced materials, coatings, and components for extreme environments, primarily serving aerospace, defense, space, and energy customers. Core offerings include thermal protection and environmental barrier coatings, refractory and platinum group metal components, additive-manufactured propulsion hardware, and ASCENT green-propellant thrusters sold through its Rubicon Space Systems division. The company is vertically integrated, performing powder development, coating, machining, assembly, and qualification testing in-house in Huntsville, Alabama.
Product overview
Plasma Processes is a materials manufacturing company offering a portfolio of advanced coatings, propulsion components, and manufacturing services for extreme environments. The core product lines include Coatings and Shielding (TPS, TBC, EBC), High Performance Components and Assemblies (rocket nozzles, thrust chambers), and the Rubicon Propulsion Products sub-brand (ASCENT-based thrusters including 0.1N, 1N, 5N, and 110N variants). Supporting products include Commercial Aerospace Components, Materials and Testing services, Crucibles, and the proprietary El-Form® electrodeposition technology. The company operates manufacturing facilities in Huntsville, Alabama with capabilities spanning coating processes, additive manufacturing, machining, material development, and engineering services.
Differentiator
Problem solved
Functional benefit
Brands
- Rubicon Space Systems: Propulsion division of Plasma Processes focused on ASCENT-based green propellant thrusters and propulsion systems for satellites and spacecraft.
- El-Form
Products and services
- Coatings and Shielding Advanced thermal protection systems (TPS), thermal barrier coatings (TBC), environmental barrier coatings (EBC), radiation shielding, ablative, abrasive, corrosion, and anti-erosion coatings for extreme environments, withstanding temperatures up to 4500°F+ (~2500°C). Used by aerospace, defense, space, energy, and medical device customers.
- High Performance Components and Assemblies Advanced propulsion components and assemblies for solid rocket motors (SRMs), divert and attitude control systems (DACS), rotating detonation engines (RDEs), ramjets, scramjets, and satellites, including nozzles, thrust chambers, pintles, non-eroding throats, crucibles, igniters, and electrodes. For defense and aerospace prime contractors and government agencies.
- Rubicon ASCENT Thruster Product Line
- Commercial Aerospace Components
- Materials and Testing Services
- Crucibles
- El-Form Electrodeposition Services
- Sprite Propulsion System
Quantifiable outcome
- Coating on Parker Solar Probe - closest human-made object to the sun - surviving 2,500°F+ temperatures
- +4 more outcomes
Companies that use Plasma Processes
Customer profileNamed customers20 records
Segments7 records
Ideal customer profiles4 records
Plasma Processes technology and API
TechnologyTechnology focussed Yes
API detail
- Has API
- No
- API docs
- API detail
Core technology
AI maturity
App detail
Feature6 records
Plasma Processes partnerships and signals
Strategic signalPartnerships
Six partnerships are on record, tiered core.
- GeoPlasmacoreJoint venture between Geocent (Metairie, LA) and Plasma Processes (Huntsville, AL) for advanced aerospace materials development. Partners include The University of Alabama in Birmingham and The University of Tennessee. Developed multi-functional lightweight composite materials for radiation shielding and thermal barrier coatings. Materials flew aboard ISS on MISSE-11 platform for evaluation in space environment. Funded by NASA SBIR Program for lunar habitation and deep space mission applications.
- Johns Hopkins Applied Physics Laboratory (JHAPL)coreCollaboration began in 2006 to develop and apply optical coating to Parker Solar Probe's carbon-carbon composite heat shield. Plasma Processes synthesized custom powder and scaled coating process from 1-inch square to 9-foot x 9-foot full-scale heat shield. Coating validated for flight qualification in 2015. The Parker Solar Probe is now the closest man-made object to the sun.
- Rubicon Space SystemscorePropulsion division spun off from Plasma Processes focused on ASCENT (AF-M315E) green propellant thrusters and propulsion systems. Launched in early 2020s after internal development and multiple SBIR Phase II and Phase III contracts. Sells 0.1N to 110N thrusters for satellites and spacecraft. Website at rubicon.space.
- NASAcoreMultiple NASA programs including Parker Solar Probe coating, GPIM hardware, Lunar Flashlight propulsion, and recent contract for 110N ASCENT thruster development. NASA Marshall Space Flight Center Small Business Subcontractor of the Year 2013. SBIR funding for green propulsion and advanced materials.
- Air Force Research Laboratory (AFRL)coreAFRL developed ASCENT propellant that Rubicon Space Systems commercializes. Multiple SBIR Phase II and Phase III contracts supporting ASCENT thruster development. Green propellant technology funding from MDA in 2008 building on AFRL work.
- Missile Defense Agency (MDA)coreIDIQ-approved holder for Golden Dome/DOW effort. Over 20 years of direct experience delivering flight-qualified hardware for MDA-supported programs. Green propellant technology featured in MDA Tech Update. Supports space-based and exo-atmospheric interceptors, sensors, and defensive assets.
Scale indicators8 records
Recent moves8 records
Expansion highlights6 records
Plasma Processes competitors and assessment
Company assessmentBroad incumbents
- Materion Corporation: Materion is a publicly traded specialty engineered materials supplier producing beryllium, precious metals, and refractory metal alloys for aerospace, defense, and energy. It overlaps with Plasma Processes on platinum-group and refractory metal components and serves similar Tier 1 aerospace primes.
- Oerlikon Metco: Oerlikon Metco is the global leader in thermal spray coatings, surface solutions, and additive manufacturing materials. It is the closest broad incumbent to Plasma Processes' core coatings and surface-treatment business, though it operates across many more end markets and at vastly larger scale.
- Aerojet Rocketdyne (L3Harris): Aerojet Rocketdyne, now part of L3Harris, is the largest U.S. propulsion prime and is both a customer of Plasma Processes (GPIM) and a potential competitor in chemical and electric propulsion thrusters and solid rocket motor components. Comparable as a propulsion and energetics manufacturer.
- Praxair Surface Technologies (now part of Oerlikon): Praxair Surface Technologies was a major U.S. provider of thermal spray coatings and high-temperature materials for aerospace and industrial customers before integration into Oerlikon. It is a direct historical peer to Plasma Processes' vacuum plasma spray, atmospheric plasma spray, and HVOF coating services.
- Moog Inc. Moog designs and manufactures precision motion control products including satellite propulsion thrusters, valves, and feed systems for space and defense. It is a broad incumbent competitor to Rubicon Space Systems in the in-space propulsion market and shares many of the same satellite prime customers.
Direct peers
- Stellar Industries Corp. Stellar Industries (New Hampshire) provides thermal spray coating services for aerospace, defense, and industrial customers using plasma, HVOF, and flame spray processes. It is a direct coating-services peer to Plasma Processes' core coatings/shielding business.
- Ultramet: Ultramet is a California-based advanced materials manufacturer specializing in refractory metals, ceramic composites, chemical vapor deposition, and high-temperature coatings for aerospace and defense. It is a direct specialty peer to Plasma Processes in refractory-metal coatings and propulsion component manufacturing.
- CPS Technologies Corporation: CPS Technologies produces advanced metal-matrix composites and hermetic packaging for aerospace, defense, and semiconductor applications. It is a small-cap specialty materials peer comparable to Plasma Processes in serving extreme-environment aerospace and defense applications with proprietary materials technology.
Emerging players
- Rocket Lab USA: Rocket Lab is a launch and space systems company whose Space Systems division (formerly Sinclair Interplanetary, SincLair, Planetary Systems Corp., and SolAero) provides satellite components including in-space propulsion. Comparable to Rubicon Space Systems for the satellite and constellation customer base.
- Additive Manufacturing Technologies / Velo3D: Velo3D is a metal additive manufacturing systems and parts producer serving aerospace and defense customers, with overlap on refractory and platinum-group-metal printing. Plasma Processes competes in adjacent AM service work (LPBF, plasma spray forming, El-Form) for similar space and propulsion customers.
Market position
Strengths5 records
Weaknesses5 records
Competitive moat6 records
Key risks6 records
Key highlights7 records
Customer concentration
Plasma Processes social profiles
Digital presencePlasma Processes compliance and trust
Trust signalCompliance6 records
Plasma Processes financial estimates
Financial estimateRevenue estimate
Valuation estimate
Plasma Processes leadership team
Management profileNumber of profiles
Profiles5 records
Plasma Processes subsidiaries and ownership
Company hierarchySubsidiaries2 records
Plasma Processes funding detail
Funding detailFunding overview
Funding rounds
Investors
Funding detail is available on the Subscription and Enterprise plan.Contact sales →
Plasma Processes M&A and investment
M&A and investmentM&A
Investments
M&A and investment is available on the Subscription and Enterprise plan.Contact sales →
Frequently asked questions about Plasma Processes
What does Plasma Processes do?
Plasma Processes manufactures advanced materials, coatings, and components for extreme environments, primarily serving aerospace, defense, space, and energy customers. Core offerings include thermal protection and environmental barrier coatings, refractory and platinum group metal components, additive-manufactured propulsion hardware, and ASCENT green-propellant thrusters sold through its Rubicon Space Systems division. The company is vertically integrated, performing powder development, coating, machining, assembly, and qualification testing in-house in Huntsville, Alabama.
Is Plasma Processes a public or private company?
Plasma Processes is a private company. It is classified as founder individual operated bootstrapped and is currently operating.
When was Plasma Processes founded?
Plasma Processes was founded in 1993. It employs 11 to 50 people.
Where is Plasma Processes based?
Plasma Processes is headquartered in Huntsville, United States, in the North America region.
How does Plasma Processes make money?
Three revenue lines are on record. Contract Manufacturing Services are the primary driver. The others are materials and Testing Services and propulsion Products (Rubicon Space Systems).
Who are Plasma Processes's main competitors?
Broad incumbents on record are Materion Corporation, Oerlikon Metco, Aerojet Rocketdyne (L3Harris), Praxair Surface Technologies (now part of Oerlikon) and Moog Inc.. Direct peers are Stellar Industries Corp., Ultramet and CPS Technologies Corporation. Emerging players are Rocket Lab USA and Additive Manufacturing Technologies / Velo3D.
Does Plasma Processes have an API?
No public API is recorded for Plasma Processes.
What industry is Plasma Processes in?
Plasma Processes's product category is Advanced Aerospace Materials and Coatings Manufacturing. Its primary akta.pro industry code is IMAIAKAF, Thermal Spray & Metallizing (HVOF/Plasma/Arc), with a secondary code of IMABACAF, Space Structures, Mechanisms & Thermal Control. Its NAICS code is 336415 and its SIC code is 3760.