Billed as less costly to produce and fly, the unmanned Terran 1 rocket launched from Cape Canaveral, Florida at 11.25pm (0325 GMT Thursday) 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, Wednesday’s launch proved that the rocket – whose mass is 85% 3D-printed – could withstand the rigours 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 1,250kg into low Earth orbit.
The rocket is 33.5 metres tall with a diameter of 2.2 metres.
85% 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 ever 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% 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 US$1.65 billion, mostly for the Terran R, according to CEO Tim Ellis, who co-founded the company in 2015.