As Firefly Aerospace prepares for its upcoming Alpha rocket launches, work continues apace on its next-generation Medium Launch Car (MLV) rocket with its Miranda and Vira engines, using its Briggs take a look at web site in Texas. MLV’s Chief Engineer, Miles Grey, confirmed NSF across the take a look at web site to replace the standing of the brand new automobile and engines whereas additionally noting the automobile is being designed with reusability in thoughts, involving a restoration that follows an identical path as SpaceX’s Starship Mechazilla catch system.
Since its revival in early 2017, the Texas-based firm Firefly Aerospace has been laborious at work staking its declare within the small satellite tv for pc launch market. Having developed, examined, and flown its Alpha launch automobile a number of occasions, Firefly is bolstering itself with different end-to-end programs, together with on-orbit administration and lunar providers.
Now, Firefly is taking the following step towards constructing and launching greater rockets with its Medium Launch Car (MLV).
For Firefly, MLV will function a testomony to the corporate’s progress over time by way of dimension and scope of capabilities. Whereas Alpha stands at 29.5 m in top, MLV will tower above it at 55.7 m; Alpha can launch simply over 1,000 kg to low-Earth orbit (LEO), with MLV able to as much as 16,300 kg.
A creative render of Firefly’s Medium Launch Car/MLV in flight. (Credit score: Firefly Aerospace)
Whereas Firefly needed to develop and assemble the Alpha rocket independently as an in-house product, the corporate will obtain substantial help on MLV from a significant aerospace participant.
In cooperation with Northrop Grumman, Firefly is knee-deep in creating MLV, with qualification testing on its carbon composite constructions already underway. Stated constructions are scaled primarily up from people who make up the development of the smaller Alpha rocket.
As seen as a key future consideration of the spaceflight trade, no less than since SpaceX proved the expertise, Firefly can also be taking a look at reusability with MLV. The corporate has already downselected how they may strategy this purpose.
“The best way we strategy that is that something that doesn’t need to be on the rocket shouldn’t be on the rocket. So meaning we’re not beginning with the concept that we must always simply put legs on the factor and land it in form of the identical method,” famous MLV’s Chief Engineer, Miles Grey. “In order that signifies that we have now a floor catch system that’s not directly going to catch the rocket.”
Miles acknowledged that the thought is much like SpaceX’s system however stated that the corporate remains to be evaluating no less than three totally different choices, every with a various diploma of accuracy wanted for the booster to land.
“We’ve got perhaps three totally different (varieties) of tough architectures we’re pursuing proper now. All of them are placing in an identical quantity of effort to only get them to a degree the place we will actually say that’s the most effective one, and we will all the time look again at you realize extra conventional leg system to say like for this reason that is higher than this.”
SpaceX transitioned from the unique plans to land Starship on its touchdown legs to the catch system that has since change into famously often known as Mechazilla.
After arriving in a single day Starship B12 was lifted onto the Pad A OLM. apparently, the chopsticks lifted the booster to the very prime of the tower, in a potential take a look at associated to catch operations earlier than being lowered. @NASASpaceflight
Starbase Stay pic.twitter.com/flyDxSQnur— Elisar Priel (@ENNEPS) September 20, 2024
“Chopsticks, yeah, Mechazilla. I don’t suppose it is going to look precisely like that. There’s form of one structure that appears much like that after which there’s one that’s, there’s form of two choices there, proper? You may both have the automobile be actually good and capable of form of like cling itself on a wire or one thing like that, or you’ve gotten one thing just like the chopsticks that’s itself form of intelligent and goes to catch the rocket.”
“So we’re nonetheless going to do some form of propulsive touchdown. The engines are going to be engaged proper earlier than it will get caught since you needed to scrub off that pace a way. The one different method you are able to do that basically is one thing like a parachute. Parachutes form of inherently are going to place you in a really massive space to land, which signifies that the automobile has to have all the pieces on the automobile, which then at that time, you simply put legs on it. There’s no level happening the highway of airbags and complex different stuff like that.”
The automobile may even embrace grid fins, one other well-known sight on rockets that conduct a propulsive return and touchdown. In contrast to SpaceX, Firefly can also use the fins as a “laborious level” for capturing the returning rocket.
“Anytime you’re designing a rocket, you all the time wish to make it possible for the mass that you just’re doing, you realize, whenever you put mass on the rocket, you need it to do two issues. It’s form of like enjoying chess. You don’t ever wish to make a transfer that simply does one factor. You need that transfer to really make three issues occur,” added Miles.
“So whenever you put an engine on the rocket, for a traditional rocket, form of all that does is make it go up, proper? However when you have it on there already, you ought to be utilizing that engine to land by some means. As a result of there’s a bunch of mass you’re carrying with you, all that propellant that you’ve got with you is additional mass, so that you wish to be extremely incentivized to make use of that. So some form of propulsive touchdown is basically fascinating.”
“We principally know we’re gonna put grid fins on. These grid fins are a tough level, they’re a pure laborious level. There’s a bunch of mass there, it doesn’t matter what. You may already cling the rocket from these. So that you would possibly as effectively catch a few of these. So a lot of the catches that we’re taking a look at embrace the grid fins. Or one thing that’s carefully coupled to the laborious level.”
Firefly Briggs from the air. (Credit score: Gary Blair for NSF/L2)
As well as, the primary MLV strain and propellant tanks have been constructed and are about to be examined at Firefly’s 200-acre Rocket Ranch developmental facility in Briggs, Texas.
These have been constructed utilizing an Automated Fiber Placement (AFP) machine that may lay up greater than 200 lbs of carbon fiber per hour. This allowed Firefly to provide the most important constructions for MLV in 30 days — a lot sooner and cheaper than different processes.
To enhance this and different MLV improvement processes, the corporate doubled the dimensions of its Briggs campus from 90,000 sq. toes to greater than 200,000 sq. toes. This noticed the addition of two new manufacturing buildings and two new take a look at stands — one for structural testing and one other for engine qualification.
The take a look at article, dubbed Shorty as a result of it’s shorter than an everyday MLV first stage, will permit engineers to validate the manufacturing technique of the MLV tanks with no need to construct a whole first stage.
Firefly is taking many classes and applied sciences acquired from its Alpha rocket and carrying it over to MLV, together with the tap-off engine cycle that will likely be used on the uprated Miranda and Vira engines. This allows the corporate to quickly construct, take a look at, and iterate on the bigger automobile extra effectively.
Miranda on the take a look at stand at Briggs. (Credit score: Tyler Grey for NSF)
Seven Miranda engines will enhance the MLV off the launch pad. They’ve additionally been designed with capabilities equivalent to deep throttling to help the reusability strategy.
The rocket may even retain some flight-proven programs from the Antares program, thereby offering further upgrades. The primary stage of MLV will characteristic many similarities to the booster stage for the Antares 330, which can also be being co-developed by Firefly and Northrop Grumman.
All in all, the leap in efficiency from Alpha to MLV serves as a boon for Firefly’s enterprise mannequin — and leaves further wiggle room for the corporate to introduce partial reusability into the system.
(Lead picture: the Firefly Aerospace Rocket Ranch testing campus. Credit score: Gary Blair for NSF/L2)
