THE NEW SPACE RACE: Neutron’s first launch slips again amid trouble with carbon composites.
Engineers discovered voids, or air pockets, between layers of carbon fiber that make up the domes’ composite structure. Carbon composite manufacturing involves laying down carbon fiber layers in a mold, then curing, or heating, the material to bind the fibers together. But this is a tricky process, especially for large structures that won’t fit into an autoclave, a high-pressure thermal curing chamber common in modern aerospace factories.
The Neutron rocket’s first stage is the “largest pressurized structure ever made out of carbon composite,” Beck said. “Because of its scale, we’ve had to develop new out-of-autoclave processes to build Neutron, and this includes custom cure cycles for the very large pieces, like the forward and aft domes for the propellant tanks on Stage One.”
Space is hard, even when you don’t have to invent all-new manufacturing techniques.
