Relativity Space has secured its inaugural contract with a U.S. government entity, and notably, it’s with a leading defense organization. The launch provider’s rockets, which are uniquely manufactured using 3D-printing technology, are ideally suited for a challenging mission Lockheed Martin is conducting under NASA’s Tipping Point initiative.

This mission centers around the testing of twelve distinct cryogenic fluid management systems, including liquid hydrogen, a substance known for its handling complexities. The tests will be performed on a single spacecraft in orbit, demanding a particularly intricate design and construction process.

While Lockheed Martin and its NASA collaborators will be responsible for the design and construction of the payload and its cryogenic systems, close collaboration with the launch provider will be essential throughout development and, especially, during the preparations for launch.

Tim Ellis, founder and CEO of Relativity, highlighted that the company’s comprehensive 3D-printing approach – building the entire rocket from top to bottom – is particularly advantageous for this undertaking.

“We are developing a customized payload fairing with the specific payload loading interfaces required, along with tailored fittings and adapters,” he explained. “However, it will maintain a smooth exterior, appearing as a conventional rocket to the casual observer,” he added.

Although every fairing, which is the outer shell protecting the payload during launch, is inherently custom-built, this one requires a significantly greater degree of personalization. The sensitivity of operating a dozen cryogenic systems and testing them right before launch necessitates numerous modifications that would traditionally lead to substantial manufacturing challenges.

“Current manufacturing techniques haven’t evolved significantly in the past 60 years,” Ellis pointed out. “They rely on fixed tooling and large machines that, while impressive, are limited to producing a single shape or object designed manually. Creating such tooling can take 12 to 24 months.”

This is where Relativity’s approach differs significantly.

“Using our 3D-printing process, we can produce the entire fairing in under 30 days,” Ellis stated. “Furthermore, it’s software-controlled, allowing us to easily modify the file to alter the dimensions and shape. For this specific component, we can implement custom features more rapidly and adapt to changes. Even with a launch date three years away, there will inevitably be last-minute adjustments, and we can readily accommodate them. Otherwise, the design would need to be finalized immediately.”

Ellis expressed his enthusiasm about the opportunity to publicly collaborate on a mission with such a prominent contractor. These large companies manage substantial government funding and participate in numerous launches, making it crucial to establish a positive relationship. A mission like this, while complex, presents a relatively low-risk opportunity (compared to crewed missions or launches of high-value satellites) for Relativity to demonstrate its capabilities. (The company has already secured pre-sales for many of its launches, indicating strong interest in its 3D-printed launch vehicles, but additional opportunities are always welcome.)

The company anticipates reaching space before this, assuming plans proceed as scheduled. The first orbital test flight is currently planned for late 2021. “We are currently 3D-printing the launch hardware, over the past few weeks,” Ellis noted.

The NASA Tipping Point program, which is providing Lockheed Martin with an $89.7 million contract for this experiment, aims to support promising technologies in achieving commercial viability, as its name suggests. By awarding hundreds of millions of dollars annually to companies developing innovations like lunar landers and robotic arms, the program functions as a sort of agency-level venture capital fund.