Development, manufacturing and testing of small launcher structures from Portugal

TL;DR

This paper discusses the development, manufacturing, and testing of small launcher structures in Portugal, focusing on low-cost, lightweight, and custom solutions for small satellite launches, integrating cross-industry technologies.

Contribution

It introduces innovative design and manufacturing approaches for small launcher structures, emphasizing industrialization and supply chain development for the New Space sector.

Findings

Successful development of a versatile Kick-Stage and Payload Fairing

Implementation of cross-industry manufacturing concepts

Lessons learned from manufacturing and testing processes

Abstract

During the last decades the industry has seen the number of Earth orbiting satellites rise, mostly due to the need to monitor Earth as well as to establish global communication networks. Nano, micro, and small satellites have been a prime tool for answering these needs, with large and mega constellations planned, leading to a potential launch gap. An effective and commercially appealing solution is the development of small launchers, as these can complement the current available launch opportunity offer, serving a large pool of different types of clients, with a flexible and custom service that large conventional launchers cannot adequately assure. Rocket Factory Augsburg has partnered with CEiiA for the development of several structures for the RFA One rocket. The objective has been the design of solutions that are low-cost, light, and custom-made, applying design and manufacturing concepts as well as technologies from other industries, like the aeronautical and automotive, to the aerospace one. This allows for the implementation of a New Space approach to the launcher segment, while also building a supply chain and a set of solutions that enables the industrialisation of such structures for this and future small launchers. The two main systems under development have been a versatile Kick-Stage, for payload carrying and orbit insertion, and a sturdy Payload Fairing. Even though the use of components off-the-shelf have been widely accepted in the space industry for satellites, these two systems pose different challenges as they must be: highly reliable during the most extreme conditions imposed by the launch, so that they can be considered safe to launch all types of payloads. This paper thus dives deep on the solutions developed in the last few years, presenting also lessons learned during the manufacturing and testing of these structures.