The high cost of traditional hypersonic nozzles limits accessibility for academic and research institutions. Currently, many nozzles are machined from billet aluminum, costing between $80,000 and $120,000 per nozzle. In this work, we present the design, fabrication, and testing of a novel composite hypersonic nozzle capable of generating Mach 6 flow with the fabrication cost being at a fraction of a conventional nozzle. We will also compare this with a minimal cost aluminum nozzle. Through composite manufacturing, we built a Mach 6 nozzle that withstands 1,000 psi—at a cost of under $1,500. By significantly reducing fabrication costs, this work increases access to hypersonic research, enabling more institutions to explore high-speed aerodynamics with hands-on experimentation. The development process involved advanced design and simulation tools, including Eilmer 4 for contour optimization, ANSYS ACP for composite layup analysis paired with static structural evaluation, SolidWorks for CAD modeling, and Markforged Preform was used to fabricate the mold for the composite part. The nozzle was manufactured using a two-part plug mold, an uncommon but effective technique for achieving the required geometry. The mold for the composite nozzle was 3D-printed using stereolithography-additive (SLA) technology, followed by a detailed post-processing workflow to ensure a high-quality surface finish. To ensure an accurate internal flow profile, vacuum bagging was used to precisely form the inner contour of the nozzle, as external geometry was not a critical design constraint. Both the composite nozzle and the aluminum nozzle will be tested in an economic Ludwieg tube (a high-speed wind tunnel) to assess flow uniformity and structural integrity. This poster provides a comprehensive guide to designing, simulating, and fabricating composite hypersonic nozzles, which will be compared to the fabrication process of an aluminum nozzle. This includes a detailed bill of materials outlining all necessary components and fabrication tools. By sharing our methodology, we aim to enable more institutions to conduct hands-on hypersonic research while significantly minimizing costs. Our approach demonstrates that high-performance hypersonic testing capabilities can be achieved through cost-effective and scalable fabrication techniques.