Case Study: Phase Four achieves mass-producible, 80% lower-cost electric propulsion with Xometry

Phase Four Launches Scalable Electric Propulsion (EP) System with Xometry

Phase Four, an in-space propulsion startup, set out to build Maxwell — a modular, longer-lived electric propulsion (EP) system sized for small satellites and priced an order of magnitude lower than legacy Hall-effect thrusters. To meet strict aerospace requirements and shorten lengthy lead times, Phase Four turned to Xometry for certified aerospace manufacturing and supplier management, using Xometry’s ISO 9001:2015/AS9100 supplier network and Instant Quoting Engine to communicate complex CAD models and drawings.

Xometry manufactured seven critical parts (including a single‑billet unibody exoskeleton), provided material/hardware traceability and coatings, and used its broad supplier network to deliver parts on an accelerated timeline. The result: parts that met tight tolerances and flight documentation, a quoted/ordered/received turnaround in 2 weeks versus 8–10 weeks previously, a reduction of total EP system lead time from 1.5+ years to 6 months (with a 3‑month target), sourcing up to 5× faster, and manufacturing cost reductions that help Phase Four lower product price by about 80% — all enabled by Xometry.

Phase Four

Austin Prater

Phase Four