Carbon Composites Usher in New Era of Rocket Manufacturing

Rocket Lab, a leader in low-cost launch services and space systems, has embarked on a new chapter in rocket manufacturing with the installation of the largest automated fiber placement (AFP) machine of its kind. This 90-tonne, 39-foot-tall robotic marvel, custom-built by Electroimpact in Mukilteo, WA, is designed to automate the production of the largest carbon-composite rocket structures in history for Rocket Lab's Neutron rocket.

The AFP machine is capable of laying continuous carbon-fiber composite at an impressive rate of 328 feet per minute and can move up to 98 feet in length. It features a fully automated real-time inspection system that identifies minuscule defects in the laminated carbon composite, ensuring high-quality standards for reusable Neutron launches.

Custom-built AFP machine is designed to automate production of the largest carbon composite rocket structures in history. Image courtesy of Rocket Lab.

Impact on manufacturing efficiency

The introduction of the AFP machine is expected to significantly enhance manufacturing efficiency by saving more than 150,000 hours in the production process of the Neutron rocket. This machine will automate the creation of major components, including the 91-foot-long interstage and fairing, the 22.9-foot-diameter first stage, and the 16.4-foot-diameter second stage tank. Rocket Lab's founder and CEO, Sir Peter Beck, emphasized the importance of this innovation, stating that the machine combines proprietary carbon-composite technology, additive manufacturing, and autonomous robotics to produce large-scale aerospace components. This advance not only supports Neutron's launch cadence but also benefits Rocket Lab's Electron launch vehicle and other spacecraft customers.

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Additional industry collaborations

Beyond Rocket Lab, the space industry is seeing a surge in collaborations and advances in composite materials. Case in point: South Korea's Kolon Group has launched Kolon Spaceworks, a new company focused on integrating composite materials businesses within the group. This initiative aims to maximize synergies in material combinations and production methods, enhancing competitiveness and expanding application areas from the sea to outer space.

Additionally, Syensqo (formerly Solvay) and micro-launch vehicle operator Orbex, based in Forres, Scotland, have entered into a strategic collaboration to integrate advanced adhesive, composite, and specialty polymer materials into Orbex's launch vehicles. This partnership focuses on improving the performance, durability, and sustainability of orbital launch systems, with a particular emphasis on weight reduction, thermal resistance, and structural integrity.

Reduced mass, increased strength, thermal resistance

The adoption of carbon composites in rocket manufacturing presents numerous advantages, including reduced weight, increased strength, and enhanced thermal resistance. These materials are crucial for developing next-generation aerospace technologies that can withstand the harsh conditions of space, while increasing payload on account of their light weight.

However, the industry faces challenges such as the high cost of composite materials and the need for specialized manufacturing processes. As companies like Rocket Lab and their partners continue to innovate, the focus will be on overcoming these challenges to make carbon composites a standard in rocket manufacturing.

Note: The author holds shares in Rocket Lab.