Modular low Earth orbit satellite system could unlock space-based solar power
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Revolutionizing Rocket Production: Rocket Lab's Automated Fiber Placement Machine
For years, building large composite rockets has been a labor-intensive and time-consuming process, requiring engineers to spend countless hours manually laying thousands of layers of carbon fiber, ensuring precise alignment and quality.
However, Rocket Lab has now simplified this process with its innovative Automated Fiber Placement (AFP) machine, streamlining the process from weeks to a single day. This groundbreaking technology has the potential to transform the way rockets are produced, enabling faster, more efficient, and cost-effective production.
The company has installed this massive 90-ton machine at its Neutron rocket factory in Middle River, Maryland, to 3D-print its Neutron rocket. This giant 3D printer can make carbon fiber layers at incredible speeds, building complex structures with unmatched precision. The AFP machine is a 39-foot (12-meter) robotic machine, custom-built by Electroimpact in Washington, capable of 3D printing carbon-fiber layers at an astonishing speed of 328 feet (100 meters) per minute while moving up to 98 feet (30 meters) in length.
The machine will fully automate the production of the Neutron's large composite structures, including panels for the interstage and fairing, first stage tank, and second stage tank. One of the key features of the machine is its built-in inspection system, which can automatically check for tiny defects in the carbon fiber composite material as it is being laid down. If the system finds a defect, it will alert the operator, allowing them to fix it before the machine continues to the next layer. This ensures that the launch vehicle's structures meet Rocket Lab's high-quality standards, necessary for reusable Neutron launches.
The AFP machine will dramatically cut down on production time, saving over 150,000 hours. This will enable Rocket Lab to launch more frequently and at a lower cost, making it a game-changer for the aerospace industry. The machine will not only be used to produce the Neutron rocket but also various small carbon composite structures, including Electron first stages, and other spacecraft parts. Rocket Lab plans to launch the first Neutron rocket in 2025.
The use of carbon fiber composites on a massive scale is a pioneering effort by Rocket Lab, offering incredible strength and lightweight properties, making it ideal for space travel. The company's proprietary flight-proven carbon composite technology, additive manufacturing, and autonomous robotics will enable the design and build of large-scale aerospace components at a pace that will support not only Neutron's launch cadence but also Electron and carbon composites structures for spacecraft customers.
The AFP machine is a testament to Rocket Lab's commitment to innovation and its goal of making space travel more accessible and affordable. By leveraging cutting-edge technology, the company is poised to disrupt the aerospace industry and pave the way for a new era of space exploration. With its Automated Fiber Placement machine, Rocket Lab is revolutionizing the way rockets are produced, enabling faster, more efficient, and cost-effective production, and setting a new standard for the industry.
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