Rocket Lab Booster Recovery: A Major Step Towards Reusability

Rocket Lab has achieved a significant breakthrough with the successful recovery of an Electron launch vehicle’s first stage following a controlled splashdown in the Atlantic Ocean. This accomplishment represents a key step forward in the company’s efforts to develop a reusable rocket system. Shortly after the operation, CEO Peter Beck described the mission as “a complete success,” and it also generated $286,092 in donations for charitable causes.

This event marked the first major trial of Rocket Lab’s upgraded Electron rocket, featuring a redesigned interstage – the section positioned between the first stage booster and the second stage, which carries the payload into orbit – enabling a controlled descent of the booster after separation.

The long-term objective involves capturing the booster mid-air using a helicopter, but for this initial test, the team opted for a splashdown. As Beck explained, “Pulling rockets out of the ocean is just not fun.”

Prior to launch, a general prediction of the descent location is already established, based on the carefully calculated rocket trajectory and thorough weather monitoring. Throughout the launch, the anticipated descent area is refined using real-time data transmitted from the rocket itself.

“We will have a ship stationed downrange with a helicopter operating from it. This helicopter will take off simultaneously with the rocket and position itself above the predicted reentry point,” Beck detailed. “As soon as we transition control to the first stage, it begins transmitting its projected impact point in real-time, creating a continuous feedback loop.”

He also clarified that the helicopter would not be endangered by debris in the event of a launch anomaly, as the trajectory would differ significantly in such a scenario.

Following the second stage’s detachment, the first stage initiated its descent, reaching approximately Mach 2 before deploying a pilot chute, followed by a drogue chute for about a minute to reduce its speed. Finally, the main glider chute was deployed, allowing for a predictable cruise path until retrieval by the helicopter. In this instance, it was permitted to splash down, landing “within a few miles” of the predicted impact zone at a speed of roughly nine meters per second, or 20 miles per hour.

Image Credits: Rocket Lab

Beck expressed his satisfaction from mission control, noting, “Considering the state of the sea, I’m relieved I wasn’t on the boat. The return trip was over five-meter swells. I don’t have particularly strong sea legs,” he confessed. Despite the challenging conditions, the descending stage relayed accurate, albeit limited, telemetry, which he monitored while the second stage continued its flight. “It felt like cheating, to divert attention from the ascent to observe the reentry.”

(He further remarked that “if you were present in the room, you would likely have described me as a giggling schoolboy.” Another Rocket Lab representative on the call corroborated this observation.)

The recovery team promptly collected the booster after splashdown, and engineers are currently dismantling it to assess the various components for wear and tear. “The stresses experienced during reentry are greater than those during ascent,” Beck explained, meaning the hardware encounters different and more demanding conditions during its semi-controlled descent compared to the carefully planned launch.

While some components are expected to be recertified for future use, the engines and certain other parts will not be flown again. “It wouldn’t be fair to the engines, considering the stress they endured. It got quite hot down there,” Beck stated.

Image Credits: Rocket Lab

However, this is all part of the planned process. Data gathered from this descent will be used to modify and strengthen the first stage’s heat shield and components to better withstand the challenges of reentry. “We will address the engines in the future,” Beck said. “The ultimate goal is to recover the entire stage, refuel it, and launch it again.”

Although this is a complex undertaking, requiring thorough inspection and recertification of every component, it can be conducted concurrently with the main Electron production line – which Beck stated is currently producing a launch vehicle every 30 days and becoming increasingly efficient – it is anticipated to significantly increase the company’s rocket inventory.

The financial implications of recovery, utilizing recertified hardware, and other related aspects are still being evaluated, Beck emphasized. “However, the first stage represents the majority of the cost of building an Electron, so improving its reusability can fundamentally change the vehicle’s economics. We hope to have a clearer understanding next year, but that may not be possible,” he said.

One aspect appears certain: reusable rockets are essential for reducing launch costs.

The launch was also a success in another way: it included the deployment of a 3D-printed gnome whose journey was funded by Gabe Newell, the founder of Valve Software. He pledged to donate one dollar to Starship Children’s Hospital for every view of the launch’s live stream, resulting in a donation of $286,092.

Gnome Chompski, as the gnome is known, likely burned up upon reentry, but enjoyed a brief and memorable trip to space, providing some striking photographs.

Image Credits: Rocket Lab