Rocket Lab has initiated the installation of an Automated Fiber Placement (AFP) machine at its Neutron rocket production facility in Middle River, Maryland. This robotic system, custom-built by Electroimpact in Washington, is designed to automate the production of large carbon composite structures for the Neutron rocket.
Weighing 99 tons (90 tonnes) and standing 39 feet (12 meters) tall, the AFP machine is capable of moving along a length of up to 98 feet (30 meters) and laying down continuous carbon fiber composite material at a speed of 328 feet (100 meters) per minute. It will fabricate components such as the interstage and fairing, the first stage, and the second stage tank of the Neutron rocket.
The machine includes a fully automated real-time inspection system that monitors the carbon fiber composite material during placement, detecting any defects in the laminate. If issues are identified, the system alerts the operator before proceeding to the next layer, ensuring adherence to quality standards.
The introduction of the AFP machine is expected to reduce manufacturing time by over 150,000 hours as Neutron’s carbon composite structures enter full-scale production. In addition to producing large structures for the Neutron rocket, the machine will handle smaller carbon composite components for Rocket Lab’s Electron launch vehicle and other aerospace applications, including spacecraft structural panels, solar panel substrates, and carbon composite tanks.
Rocket Lab’s founder and CEO, Sir Peter Beck, noted that the integration of this robotic system with the company’s proprietary carbon composite technology and additive manufacturing techniques will facilitate the production of large-scale aerospace components at an accelerated pace, supporting both the Neutron rocket and other projects.
The deployment of the AFP machine at Rocket Lab’s Middle River facility reflects an advancement in the company’s manufacturing processes, contributing to its capabilities in meeting the demands of the space industry.
