First 3D-printed rocket lifts off but fails to reach orbit

The world’s first 3D-printed rocket suffered an ‘anomaly’ after take-off.

Relativity says its 3D-printed versions use 100 times fewer parts than traditional rockets and can be built from raw materials in just 60 days. Picture: AFP

The world’s first 3D-printed rocket launched successfully, marking a step forward for the California company behind the innovative spacecraft, though it failed to reach orbit.

Billed as less costly to produce and fly, the unmanned Terran 1 rocket launched from Cape Canaveral, Florida, on Thursday (AEDT) but suffered an “anomaly” during second-stage separation as it streamed towards low Earth orbit, according to a livestream broadcast by aerospace startup Relativity Space.

The company did not immediately give further details.

While it failed to reach orbit, the launch proved that the rocket – whose mass is 85 per cent 3D-printed – could withstand the rigors of lift-off.

The successful launch came on the third attempt. It had originally been scheduled to launch on March 8 but was postponed at the last minute because of propellant temperature issues.

A second attempt on March 11 was scrubbed due to fuel pressure problems. Had Terran 1 reached low Earth orbit, it would have been the first privately funded vehicle using methane fuel to do so on its first try, according to Relativity.

Terran 1 was not carrying a payload for its first flight, but the rocket will eventually be capable of putting up to 1250kg into low Earth orbit.

The rocket is 33.5m tall with a diameter of 2.2m.

A total of 85 per cent of its mass is 3D-printed with metal alloys, including the nine Aeon 1 engines used in its first stage and the one Aeon Vacuum engine employed in the second.

It is the largest 3D-printed object and was made using the world’s largest 3D metal printers, according to the Long Beach-based company.

Built in 60 days

Relativity’s goal is to produce a rocket that is 95 per cent 3D-printed. Terran 1 is powered by engines using liquid oxygen and liquid natural gas – the “propellants of the future,” capable of eventually fueling a voyage to Mars, Relativity says.

SpaceX’s Starship and Vulcan rockets being developed by United Launch Alliance use the same fuel.

Relativity is also building a larger rocket, the Terran R, capable of putting a payload of 20,000kg into low Earth orbit.

The first launch of a Terran R, which is designed to be fully reusable, is scheduled for next year.

A satellite operator can wait for years for a spot on an Arianespace or SpaceX rocket, and Relativity Space hopes to accelerate the timeline with its 3D-printed rockets.

Relativity said its 3D-printed versions use 100 times fewer parts than traditional rockets and can be built from raw materials in just 60 days.

Relativity has signed commercial launch contracts worth $US1.65bn ($2.46bn), mostly for the Terran R, according to CEO Tim Ellis, who co-founded the company in 2015.