Rocket Lab USA, Inc. (Nasdaq: RKLB), a leader in innovative space technology, has commenced the installation of a state-of-the-art Automated Fiber Placement (AFP) machine designed to revolutionise the production of its Neutron rocket. This new 90-tonne AFP machine, custom-built by Electroimpact, a renowned aerospace manufacturing company based in Washington, promises to significantly streamline the manufacturing process and cut down production time by around 150,000 hours.

Revolutionary AFP Machine to Accelerate Production

The AFP machine, which weighs an impressive 99 tons and stands 39 feet tall, is the largest of its kind ever constructed. It has recently completed final acceptance testing and is now being integrated into Rocket Lab’s Space Structures Complex in Middle River, Maryland. This advanced robotic system will automate the creation of large carbon composite structures, including the crucial components of the Neutron rocket: the 91-foot interstage, 22.9-foot diameter first stage, and the 16.4-foot diameter second stage tank.

The machine can move up to 98 feet in length and lay down continuous carbon fiber composite at a rate of 328 feet per minute. It also features an automated real-time inspection system that detects and corrects minor defects in the composite material, ensuring that the Neutron rocket’s structural components meet Rocket Lab’s rigorous quality standards. This enhancement is expected to bolster the efficiency and precision of the rocket production process.

Expert Insights on the AFP Machine’s Impact

Peter Beck, Founder and CEO of Rocket Lab, emphasised the importance of this AFP machine in the company’s efforts to build the world’s largest carbon composite rocket. Beck noted, “We’re combining our proprietary flight-proven carbon composite technology, additive manufacturing, and autonomous robotics to design and build large-scale aerospace components. This will not only support Neutron but also benefit our Electron launch vehicle and other aerospace projects.”

According to industry experts, the introduction of such advanced manufacturing technology aligns with broader trends in aerospace innovation, where automation and material science play pivotal roles in improving production efficiency and reducing costs. The AFP machine is expected to set a new standard for the industry, particularly in the field of composite material manufacturing, which is crucial for the development of high-performance rockets.

Broader Implications and Future Applications

The AFP machine’s capabilities extend beyond the production of Neutron rocket components. It will also be utilised for the creation of smaller carbon composite structures, including the first stages of Rocket Lab’s Electron launch vehicle. Furthermore, it will support the production of structural panels, solar panel substrates, and custom projects for various aerospace applications.

Neutron, Rocket Lab’s new medium-lift reusable launch vehicle, is designed to carry up to 13,000 kg to low Earth orbit. It aims to facilitate satellite constellations, support national security missions, and enable human exploration beyond Earth’s orbit. Neutron’s propulsion system, featuring the new 3D-printed Archimedes engine, promises rapid reusability, deep throttle capabilities, and propulsive landings. Scheduled to commence operations in 2025, Neutron will be launched and tested from Rocket Lab Launch Complex 3 at the Mid-Atlantic Regional Spaceport on Wallops Island, Virginia.

Industry Context and Future Prospects

The aerospace industry has increasingly focused on integrating advanced manufacturing technologies to enhance production capabilities and reduce costs. The adoption of AFP machines and similar technologies is expected to play a significant role in shaping the future of space exploration and satellite deployment. As Rocket Lab continues to innovate, the company’s advancements in manufacturing technology will likely have a ripple effect across the industry, driving further improvements in efficiency and performance.

  Aerospace Industry, Archimedes engine, Carbon composite technology, Electroimpact, Electron launch vehicle, Inc., Middle River MD, NASA Wallops Island, Neutron rocket, Rocket Lab USA