Rocket Lab’s automated fiber placement (AFP) machine is reported to lay down continuous carbon fiber composite at a rate of 328 feet per minute. (Photo: Business Wire)
Rocket Lab USA’s machine is expected to save more than 150,000 manufacturing hours in the rocket’s production process.
LONG BEACH, Calif.—A new automated fiber placement (AFP) machine will enable Rocket Lab USA, Inc., to automate production of what are reported to be the largest carbon composite rocket structures in history.
Rocket Lab recently began installing the custom-built AFP machine, reportedly the largest of its kind, into the company’s Neutron rocket production line at its Space Structures Complex in Middle River, Maryland, the company said in a release.
The 99-ton, 39-foot (12-meter) robotic machine, American-made by Electroimpact in Washington, had just completed final acceptance testing with the manufacturer. It will automate production of all large composite structures of the Neutron launch vehicle, including the panels that make up the 91-foot (28 meter) long interstage and fairing, 22.9-foot (7-meter) diameter first stage, and the 16.4 foot (5-meter) diameter second stage tank, according to the release.
Rocket Lab is a provider of space launch services, space systems, and spacecraft components—including carbon composite structures and integrated assemblies—for the aerospace industry. Electroimpact is a designer and manufacturer of aerospace tooling and automation systems.
The autonomous machine can reportedly move up to 98 feet (30 meters) in length and lay down continuous carbon fiber composite at a rate of 328 feet (100 meters) per minute. It has a fully automated, real-time inspection system that hunts for miniscule defects throughout the laminated carbon composite and alerts the machine operator of any issues before the machine begins laying down the next layer. This provides additional assurance that the critical structures of the launch vehicle meet Rocket Lab’s high quality standards required for reusable Neutron launches, the company said.
As Neutron’s carbon composite structures move into full-scale production, the autonomous machine is expected to introduce time-savings of 150,000-plus manufacturing hours into the production process, Rocket Lab said in the release.
“As we build the world’s largest carbon composite rocket, it makes sense that we require a world-first carbon composite fiber placement machine,” said Rocket Lab CEO and founder Peter Beck, in the release. “We’re combining our proprietary flight-proven carbon composite technology, additive manufacturing, and autonomous robotics to design and build large-scale aerospace components at a pace that will support not only Neutron’s launch cadence, but support Electron and carbon composites structures for our spacecraft customers, too.”
The AFP machine will also be leveraged to print smaller carbon composite Neutron structures, first stages of Rocket Lab’s Electron launch vehicle, and other flight-proven carbon composite structures for space. They include spacecraft structural panels and assemblies, solar panel substrates, carbon composite tanks and primary structures, and custom projects for the aerospace industry.
“We worked closely with our excellent partners at Electroimpact to create this robot and we’re thrilled with the results,” Beck said. “It’s an innovative machine producing a next-generation rocket from one of the birthplaces of the aerospace industry in Baltimore, and we can’t wait to see its first carbon composite printed panels come off the production line soon.”
Neutron is the new medium-lift reusable launch vehicle by Rocket Lab. Capable of carrying up to 13,000 kg to low Earth orbit, Neutron is designed to deliver constellations of satellites to space at once, as well as important national security missions and human exploration beyond Earth’s orbit.
Powering Neutron is Rocket Lab’s new 3D printed reusable rocket engine Archimedes, an oxygen-rich staged combustion engine using liquid oxygen and methane propellants that is designed for rapid reusability, deep throttle ability for multiple engine burns in space, and for propulsive landings when returning to the launch site, the company said.