Rocket Lab's Neutron medium payload rocket provides an innovative advance in space travel - the largest composite rocket ever built. Initially, hundreds of layers and thousands of square feet of carbon fiber were laid down by hand onto a mold, taking a massive team weeks to complete.
The 39-foot-tall carbon composite 3D printer can now lay down 328 feet of carbon fiber per minute, which can be done in a day thanks to Rocket Lab’s new automated fiber placement (AFP) machine.
You can think of it similar to a 39-foot-tall (12-meter), 75-ton autonomous 3D printer that can print out layers of carbon fiber at 328 feet (100 meters) per minute. Instead of "printing" parts, sheets of carbon fiber are laid out layer by layer in different directions to increase the strength and stiffness of each structure. With a lateral movement capability of up to 98 feet (30 meters), the AFP is fully capable of laying down the largest components - the 91-foot (28-meter) long neutron rocket intermediate stage and fairing.
The AFP is also responsible for layering the 22.9-foot (7-meter) diameter first-stage and 16.4-foot (5-meter) diameter second-stage tanks.
As the workpiece is processed, a built-in, fully automated inspection system scans the carbon composite structure for flaws or imperfections and pauses to alert the operator before proceeding to the next layer.
SpaceX's Starship is primarily made of stainless steel (300 series "HFS", like the Cybertruck's "bulletproof" material), while Boeing's Starliner primarily uses aluminum alloy. Initially, SpaceX considered using CF composites on Starship, but ultimately chose stainless steel due to its cost-effectiveness, temperature resistance and durability.
Rocket Lab estimates that the use of AFP will make the world's largest composite reusable rocket cheaper to build and faster and easier to produce, saving more than 150,000 man-hours.
Rocket Lab's website states that the company aims to launch its first neutron rocket in 2025.