Rocket Lab Advances Electron Rocket Reusability with Successful Stage Reflight Preparation

Rocket Lab Advances Electron Rocket Reusability with Successful Stage Reflight Preparation
by Simon Mansfield
Sydney, Australia (SPX) Apr 11, 2024

Rocket Lab USA, Inc. (Nasdaq: RKLB) has unveiled plans to reintegrate a previously flown Electron rocket's first stage tank into its production line, marking a crucial step towards achieving the first reflight of the stage. This move underscores Rocket Lab's objective to position the Electron as the first reusable small orbital launch vehicle globally.

The company has achieved multiple successful recoveries of Electron first stages, employing parachutes to guide them back to Earth, landing in the ocean, and then transporting them back to the production facility by a modified boat. These recovered boosters have undergone thorough analyses to refine the reusability process, but this occasion marks the first instance of reintroducing a tank to the production line for a planned reflight.

Recovered from the 'Four of a Kind' mission on January 31, 2024, the stage has undergone more acceptance tests than any other, including tank pressurization, a helium leak check, and carbon fiber structural tests through ultrasonic and other non-destructive methods to ensure the integrity of the carbon composite fibers.

The next steps for the stage include a final fit-out and a series of stringent qualification and acceptance tests, aligning with the standards applied to new Electron tanks to confirm its readiness for reflight.

Peter Beck, Rocket Lab founder and CEO, noted the completion of their recovery and production scaling efforts as an exhilarating development, stating, Our main focus now is integrating pre-flown boosters into our standard production flow to scale up for future launches. Pending successful tests, we aim to explore further reflight opportunities next year.

Rocket Lab's iterative enhancements to the recovery process include safeguarding the Electron's structure against reentry heat and forces using innovative coatings and heat shields, refining the parachute system for consistent performance, and optimizing telemetry and marine recovery operations to secure the stages quickly post-splashdown.

The company will disclose the payload for the upcoming launch on this recovered stage following the final acceptance and qualification tests.