Launch debut of 3D-printed rocket ends in failure, no orbit

[Buster's Uncle]

Launch debut of 3D-printed rocket ends in failure, no orbit
MARCIA DUNN  Thu, March 23, 2023 at 12:26 AM EDT
AP



In this frame grab from livestreamed video provided by Relativity Space, Terran 1 launches from Cape Canaveral, Fla., late Wednesday, March 22, 2023. The rocket is made almost entirely of 3D-printed parts. (Relativity Space via AP)


CAPE CANAVERAL, Fla. (AP) — A rocket made almost entirely of 3D-printed parts made its launch debut Wednesday night, lifting off amid fanfare but failing three minutes into flight — far short of orbit.

There was nothing aboard Relativity Space’s test flight except for the company’s first metal 3D print made six years ago.

The startup wanted to put the souvenir into a 125-mile-high (200-kilometer-high) orbit for several days before having it plunge through the atmosphere and burn up along with the upper stage of the rocket.

As it turned out, the first stage did its job following liftoff from Cape Canaveral Space Force Station and separated as planned. But the upper stage appeared to ignite and then shut down, sending it crashing into the Atlantic.

It was the third launch attempt from what once was a missile site. Relativity Space came within a half-second of blasting off earlier this month, with the rocket's engines igniting before abruptly shutting down.

Although the upper stage malfunctioned and the mission did not reach orbit, “maiden launches are always exciting and today's flight was no exception,” Relativity Space launch commentator Arwa Tizani Kelly said after Wednesday's launch.

Most of the 110-foot (33-meter) rocket, including its engines, came out of the company’s huge 3D printers in Long Beach, California.

Relativity Space said 3D-printed metal parts made up 85% of the rocket, named Terran. Larger versions of the rocket will have even more and also be reusable for multiple flights.

Other space companies also also rely on 3D-printing, but the pieces make up only a small part of their rockets.

Founded in 2015 by a pair of young aerospace engineers, Relativity Space has attracted the attention of investors and venture capitalists.


https://www.yahoo.com/finance/news/launch-debut-3d-printed-rocket-042637707.html

[Unorthodox]

See so this was a successful failure.  They got to stage separation which was beyond the goal of the mission.  This company does things in a really weird manner but it is what it is. 

[Unorthodox]

Jump to 1:21 for the launch itself. 

[Unorthodox]

There's a saying in the business that sometimes the best thing is a good failure.  That's what they had here. 

[Misanthrope]

Mistakes were made.


...but as this was a prototype, that's not reasonably UNexpected.  If they learn from said mistakes, then the R&D will not have been wasted.
Glad this was an unmanned flight.

[Geo]

"We are currently waiting on an update..." 

[Unorthodox]

Mistakes were made.

I wouldn't go THAT far necessarily.  You got to realize the POINT of the launch was to prove the rocket was structurally sound enough to handle the gravity turn "MaxQ".  There were red flags for 2nd stage while it was on the pad that I don't feel the need to go into here, but since that was outside the scope of the mission, it didn't matter for the launch.  The only way to test that is with a full weight load up top.  They made it past MaxQ, and through stage separation which is really encouraging. 

I know the news article says 2nd stage lit momentarily, but I don't see that on the video.  I see it TRYING several times and probably providing solid data for what was likely a pump/line issue preventing a proper fuel mix.  This is relatively minor compared to if it had failed anywhere prior, especially as it was outside the scope of the mission. 

Next mission should test 2nd stage and a fairing, which this flight didn't have, but I wouldn't be terribly shocked to see it carrying a payload from a customer at that point either. 

[Geo]

Mistakes were made.

I wouldn't go THAT far necessarily.  You got to realize the POINT of the launch was to prove the rocket was structurally sound enough to handle the gravity turn "MaxQ".  There were red flags for 2nd stage while it was on the pad that I don't feel the need to go into here, but since that was outside the scope of the mission, it didn't matter for the launch.  The only way to test that is with a full weight load up top.  They made it past MaxQ, and through stage separation which is really encouraging. 

I know the news article says 2nd stage lit momentarily, but I don't see that on the video.  I see it TRYING several times and probably providing solid data for what was likely a pump/line issue preventing a proper fuel mix.  This is relatively minor compared to if it had failed anywhere prior, especially as it was outside the scope of the mission. 

Next mission should test 2nd stage and a fairing, which this flight didn't have, but I wouldn't be terribly shocked to see it carrying a payload from a customer at that point either.

I'm a bit surprised at that. This kind of testing costs (AFAIK) millions of bucks. It would in my opinion only be sensible to try for a test of the whole assembly, nog just one stage of it.
I can't imagine a proper ignition test of the 2nd stage and the fairing you mentioned would have added much to the launch cost. Appearantly the fuel for the second stage was already onboard, if they tried to ignite it after separation.

[Unorthodox]

Without KNOWING what their funding looks like, I know the general idea of how it would be structured. 

You're a rocket company trying to sell people on building rocket bodies out of a new proprietary alloy you've developed that can be 3d printed.  You need to prove structural integrity through Max Q to either be paid a portion on completion, or for investors waiting a successful test.  You'll be able to print custom size to fit third party 2nd and third stages, so those REALLY don't matter to you getting paid right now.  Yes, you send a second stage since it's actually better test wise than sending a dummy weight.  You may not even HAVE a fairing design as that can be pushed on customers to design for each payload or onto a third party later, that's something that can't be 3d printed* so not your problem.   

They succeeded in the mission of this test flight.  Proved first stage with flying colors.  Proved stage separation (huge). They just didn't hit the 'stretch goals'.  At this point they could probably sell first stages to companies like Lockheed or Boeing, etc and have them in charge of assembly of the rest.  Unlikely since this was a mini rocket, but possible. 

*TECHNICALLY possible to print a fairing, but by definition those are multiple pieces, not a solid structure so wouldn't work with the process they're using for the bodies.