The world's first 3D-printed rocket that reached space

From Superinnovators 21/11/23. This article is in TLDR (Too Long Didn’t Read) format which is popular in the innovation community and provides a bullet summary of information.

3D printing innovation for rockets: California-based company Relativity Space, founded in 2015, has introduced a groundbreaking approach to rocket manufacturing through 3D printing technology. Their 110ft-tall Terran 1 rocket, launched on 22nd March, 2023, from Cape Canaveral, Florida, was the first almost entirely 3D-printed rocket to reach space.

Layering metal: Relativity Space employs large-scale 3D printers to construct rockets layer by layer using metal alloys. Eighty-five percent of Terran 1, including its booster, upper stage, fairing, and engines, are 3D-printed. This makes it the largest single 3D-printed object ever constructed.

Benefits: The 3D-printing process, particularly selective laser sintering, and directed energy deposition, enables the creation of components in one piece without joints, seams, or welds. This yields rockets that are simpler, lighter, cheaper, more fuel-efficient and quicker to build.

Comparison with traditional methods: Traditional rockets are built using more time-consuming methods with numerous parts requiring assembly. 3D printing, however, allows for fewer parts and minimal tooling, representing a paradigm shift in rocket construction. Prior to Terran 1, other companies have launched rockets with partial 3D-printed components but none as extensively 3D-printed as Terran 1.

Terran R: Relativity Space are currently using learnings from Terran 1 to develop 270ft-tall Terran R, a larger, two-stage, reusable 3D-printed rocket with a max payload of 33,500 kg to Low Earth Orbit (LEO). The company are aiming to launch Terran R from Cape Canaveral Space Force Base starting in 2026.

Competing with SpaceX: With Terran R, Relativity Space are aiming to compete directly with SpaceX’s Falcon 9 launcher with a lower launch cost due to their 3D printing approach. Falcon 9 is 229.6ft-tall with max LEO payload of 22,800 kg and currently costs $67 million per launch.

Customers secured: Relativity Space have pre-sold Terran R launch service agreements with government and commercial customers totaling more than $1.8 billion.

Relativity Space has constructed the globe’s largest metal 3D printers for the production of its rockets. Credit: Relativity Space

Terran 1 on launch pad. Credit: Relativity Space

Relativity Space have built and launched the world’s first 3D-printed rocket, Terran 1, and now bringing to market Terran R, a reusable medium-to-heavy-lift launch vehicle. Credit: Relativity Space Youtube