Although it is no longer used for the rocket’s body both DED and PBF remain ubiquitous in all phases of engine development and manufacturing.
After some reorganization and an apparent disillusionment with the 3D printing technologies that enabled it to get off the ground, Relativity Space is back in full force with the latest update on the new Terran R rocket. While the new rocket’s fairings will be produced using friction stir welding of metal sheets, instead of entirely 3D printed using the Stargate WAAM system, the company is far from abandoning AM altogether. In fact, in a 42-minute, in-depth, video update, the company’s scientists and engineers highlight the many ways that AM –both PBF and WAAM – are helping Terran R take form.
Relativity Space has designed Terran R as a reusable, medium-to-heavy lift rocket built to provide faster and more affordable access to space. The rocket is engineered for high-volume performance and reliability while maintaining lower costs and shorter production timelines. By adopting an iterative design, testing, and manufacturing approach, Relativity Space ensures that the rocket is cost-effective and highly functional. Leveraging AM enables the company to operate at an unprecedented pace, allowing customers to bring their payloads to orbit quickly and efficiently. Terran R is scheduled to launch from Launch Complex 16 at Cape Canaveral Space Force Station, with its first flight planned for 2026.
Terran R’s architecture
Standing at 284 feet (86.6 meters) tall with a diameter of 17.7 feet (5.4 meters), Terran R is designed to accommodate a wide range of payloads for both commercial and government clients. The rocket’s payload fairing allows it to carry satellites and cargo to Low Earth Orbit (LEO), Medium Earth Orbit (MEO), and Geostationary Earth Orbit (GEO).
- Terran R prioritizes first-stage reusability while maintaining a high payload capacity. Depending on mission requirements, the rocket can deliver 23,500 kg to Low Earth Orbit (LEO) with downrange landing capability;
- 5,500 kg to Geosynchronous Transfer Orbit (GTO) with downrange landing; and 33,500 kg in an expendable configuration for maximum payload to LEO.
The rocket’s innovative first-stage architecture introduces several key design features to enhance reusability. Terran R minimizes the propellant required for reentry burns by employing a high-angle-of-attack reentry maneuver, improving overall efficiency. Its aerodynamic design enhances reentry stability and control authority, while a passively actuated landing leg deployment system ensures rapid reuse with a lightweight and simple mechanism. A specialized reentry heat shield on the aft end is designed for repeated use, reducing refurbishment times between flights.
Designed for rapid reusability
Terran R is engineered with full reusability in mind, incorporating features that allow for streamlined recovery and refurbishment. The reusability process follows a carefully designed sequence to ensure the first stage can return safely and be prepared for subsequent launches with minimal downtime.
After stage separation, the first stage executes a controlled flip maneuver using its cold gas Reaction Control System (RCS). This maneuver positions the stage for its next step, where engines ignite to perform an entry burn, reducing velocity and minimizing peak aerodynamic loads and heating. As the vehicle enters the atmosphere, grid fins provide additional control, stabilizing the descent.
The final landing sequence involves a carefully timed landing burn, followed by the passive deployment of the rocket’s landing legs through a command leg slider-mechanism. The first stage then touches down on a downrange recovery ship positioned in the ocean. Once recovered, the stage undergoes inspection, refurbishment, and recertification before being launched again. This rapid reusability approach enables significant cost savings and faster launch turnaround times for customers.
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