A new 3D printer, standing 12 meters tall and weighing 75 tons, is capable of spraying carbon fiber layers to rapidly manufacture the Neutron rocket, which is scheduled for launch in 2025.
Rocket Lab, a U.S.-based company, is making significant strides in the field of space exploration with its medium-lift Neutron rocket, according to New Atlas on October 20.
The 12-meter tall 3D printer can print 100 meters of carbon fiber per minute. (Photo: Rocket Lab).
Initially, the manufacturing process for the Neutron involved ordering hundreds of layers and thousands of square feet (1 foot equals 0.3 meters) of carbon fiber molded by hand, requiring a large team to work for weeks to complete. Now, with Rocket Lab’s new Automated Fiber Placement (AFP) machine, this task can be completed in just one day.
The AFP functions like an automated 3D printer, standing 12 meters tall and weighing 75 tons, spraying carbon fiber layers at a speed of 100 meters per minute. Instead of printing individual pieces, the machine places carbon fiber sheets in multiple orientations, layer by layer, providing strength and rigidity to each structure.
With the ability to move horizontally up to 30 meters, the AFP can produce the largest components—the 28-meter long interstage and the protective shell of the Neutron rocket. The machine also handles the layering of the first stage (7 meters in diameter) and the second stage’s tank (5 meters in diameter).
During the manufacturing of a component, the automated inspection system integrated within the machine scans for defects or errors in the carbon composite structure, pausing to alert the operator before proceeding to the next layer.
Simulation of the Neutron rocket. (Photo: Rocket Lab).
Rocket Lab anticipates that the use of AFP will save over 150,000 labor hours in the manufacturing of Neutron, making this rocket model cheaper, faster to produce, and easier to assemble. The company plans to launch the first Neutron rocket in 2025.
According to Rocket Lab, once completed, Neutron will become the largest composite material rocket in history. The rocket is expected to stand 43 meters tall, with a diameter of 7 meters, capable of carrying 13 tons to low Earth orbit (LEO) and is designed for reusability. In contrast, SpaceX’s Starship system is primarily made of stainless steel, while Boeing’s Starliner mainly uses aluminum alloys. Initially, SpaceX considered using CF composite materials for Starship but ultimately chose stainless steel due to cost-effectiveness, heat resistance, and durability.
