Rocket Lab Installs Advanced Carbon Composite Manufacturing System for Neutron Rocket Production

Rocket Lab Installs Advanced Carbon Composite Manufacturing System for Neutron Rocket Production
by Clarence Oxford
Los Angeles CA (SPX) Aug 09, 2024

Rocket Lab USA, Inc. (Nasdaq: RKLB), a global leader in launch services and space systems, has commenced the installation of a state-of-the-art automated fiber placement (AFP) machine at its Neutron rocket production facility in Middle River, Maryland. The machine, touted as the largest of its kind, is set to revolutionize the production of carbon composite structures for Rocket Lab's Neutron launch vehicle.

The custom-designed robotic system, weighing 99 tons (90 tonnes) and standing 39 feet tall (12 meters), was manufactured by Electroimpact in Washington. Following successful final acceptance testing, installation is now underway at Rocket Lab's Space Structures Complex. The AFP machine will be pivotal in automating the creation of major components for the Neutron rocket, including the 91-foot-long (28-meter) interstage and fairing, the 22.9-foot-diameter (7-meter) first stage, and the 16.4-foot-diameter (5-meter) second stage tank.

This cutting-edge machine can lay continuous carbon fiber composite over a span of up to 98 feet (30 meters) at an impressive rate of 328 feet (100 meters) per minute. It is also equipped with an automated real-time inspection system, which scans for even the smallest defects in the laminated composite material and alerts operators before the next layer is applied. This feature is critical in ensuring that the structures meet Rocket Lab's stringent quality standards for reusable Neutron launches.

As Neutron's carbon composite structures enter full-scale production, the AFP machine is expected to reduce manufacturing time by more than 150,000 hours.

Sir Peter Beck, Rocket Lab founder and CEO, stated, "As we build the world's largest carbon composite rocket, it makes sense that we require a world-first carbon composite fiber placement machine.

"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. We worked closely with our excellent partners at Electroimpact to create this robot and we're thrilled with the results.

"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."

The AFP machine will also be utilized for producing smaller carbon composite structures for Neutron, the first stages of Rocket Lab's Electron launch vehicle, and other critical components for space applications. This includes spacecraft structural panels, solar panel substrates, carbon composite tanks, primary structures, and other custom aerospace projects.