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New European rockets! How do they compare? // Inside RFA & ISAR's Factories!

Everyday Astronaut・45 minutes read

New space companies in Europe, like Rocket Factory Augsburg and ISAR Aerospace, are developing innovative rockets to compete in the launch industry with a focus on cost-effectiveness and reliability, utilizing automotive components and advanced technologies. Companies aim to undercut prices, achieve autonomy, and integrate vertically to compete effectively in the aerospace industry.

Insights

  • European companies like Rocket Factory Augsburg and ISAR Aerospace are developing cost-effective rockets with innovative designs and utilizing automotive components to reduce payload costs, emphasizing cost-effectiveness over mass reduction.
  • Arianespace has a history of aerospace achievements in Europe, but new companies like RFA and ISAR are emerging to compete in the launch industry, focusing on vertical integration, scalability, and full automation in production to build rockets cost-competitively, utilizing advanced technologies like 3D printing for efficiency and predictability.

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Recent questions

  • What are some emerging European space companies?

    Rocket Factory Augsburg (RFA) and ISAR Aerospace.

  • What are the key features of RFA one rocket?

    Stainless steel tanks, Helix engines, RP-1, liquid oxygen.

  • Where does the Spectrum rocket launch from?

    Andoya Spaceport in Norway and Guiana Space Center in French Guiana.

  • What are the goals of increasing chamber pressure in rocket engines?

    Achieve orbit quickly, enhance payload capacity.

  • How do European rockets like RFA one and Spectrum compete with US rockets?

    Competing for payloads.

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Summary

00:00

"Emerging European Space Companies Compete Globally"

  • Europe has a history of significant achievements in aerospace, with Arianespace being a prominent player.
  • New space companies in Europe are emerging to compete in the launch industry.
  • Rocket Factory Augsburg (RFA) and ISAR Aerospace from Germany are two such companies.
  • RFA is developing the RFA one rocket, made of stainless steel tanks with Helix engines running on RP-1 and liquid oxygen.
  • RFA one can carry 1300 kilograms to sun synchronous orbit and will launch from Saxavord Spaceport in Scotland.
  • ISAR Aerospace is building the Spectrum rocket with carbon composite tanks and Aquila engines running on liquid oxygen and liquid propane.
  • Spectrum can carry 700 kilograms to sun synchronous orbit and will launch from Andoya Spaceport in Norway and Guiana Space Center in French Guiana.
  • European rockets like RFA one and Spectrum will compete with US rockets like Firefly's Alpha for payloads.
  • RFA's cost-effective construction methods involve sheet metal and optimization tools to determine design choices.
  • ISAR Aerospace focuses on performance and scale of manufacturing, utilizing manual layup, pipe bending, and carbon fiber winding processes.

13:13

"Helix Motors: Increasing Chamber Pressure for Efficiency"

  • Helix motors are being made with a combustion chamber pressure of a hundred bar.
  • Future plans aim to increase the chamber pressure to 300 bar, but the current design is limited to a hundred bar due to time constraints.
  • The goal is to quickly achieve orbit with a hundred bar pressure, ensuring ample margin and simplicity for orbit attainment.
  • Increasing chamber pressure from a hundred to 300 bar does not alter the engine size, allowing for rocket growth and enhanced payload capacity.
  • Automotive components are utilized extensively, with modifications in material specs, heat treatments, and welding for cost-effectiveness.
  • Components like TVC actuators, brushless DC motors, ball screws, and valves are sourced from automotive applications, ensuring reliability and cost-efficiency.
  • Valves used in the vehicle are highly reliable, cost-effective, and built in large numbers, contributing significantly to the vehicle's reliability.
  • The focus is on cost-effectiveness rather than minimizing mass, with automotive solutions integrated to reduce payload costs for customers.
  • Sheet metal design is preferred for cost efficiency, with a focus on using automotive components to keep costs low.
  • ISAR emphasizes vertical integration, scalability, and full automation in production to build rockets cost-competitively, utilizing advanced technologies like 3D printing for efficiency and predictability.

25:39

"Rocket Engine Design and Testing Process"

  • The open cycle does not feed back into the main chamber; instead, it goes through the exhaust, powering two pumps on a shaft upstream.
  • Liquid oxygen enters from the top, while propane enters from the bottom.
  • A de Lavel nozzle in the turbine exhaust enhances performance by increasing exhaust velocity.
  • The oxygen flows through the main oxygen valve assembly into the chamber walls and injector head, utilizing liquid oxygen for cooling.
  • The propane flows through regen channels, with a gas generator being fuel-rich to prevent overheating.
  • The engine is spin-started using helium pressure, with a dedicated port for kickstart.
  • The compact turbo machinery powering the rocket engine is compared to turbochargers on cars, generating energy equivalent to a hundred cars.
  • The rocket undergoes cryogenic burst tests for acceptance, with pressure and drain tests conducted to ensure proper engine operation.
  • The rocket is transported to the launch site in Scotland on a truck and ferry, fitting inside a standard road container due to its size.
  • The interstage of the rocket is made of automotive-grade composite for cost efficiency, with flexible fingers allowing for adaptation to different tank diameters before welding.

38:07

Spacecraft Production and Launch Process Overview

  • To ensure perfect alignment, three spots around the circumference are measured from bottom to top before welding.
  • Centricity within one inch is acceptable for cost efficiency in production.
  • The composite interstage houses the second stage nozzle and engine, featuring a lightweight carbon structure.
  • The fairing's separation locks are pneumatic, ensuring reliable and low shock separation during flight.
  • Vents regulate depressurization speed, crucial for maintaining optimal conditions during launch.
  • The fairing's heat protection shields the carbon composite from high temperatures during flight.
  • The payload adapter is a standard EELV interface for attaching the payload fairing.
  • The thrust structure on the first stage is tested using hydraulic cylinders to simulate flight loads.
  • The hold down release interface withstands 70 tons of thrust before launch.
  • Companies focus on undercutting prices, autonomy, and vertical integration to compete in the space industry.

51:45

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