Small Sat Launcher: The Future of New Space Age

Key takeaways

The Sputnik 1, the first small-lift launch vehicle, was developed by the Soviet Union, and it was successfully launched on October 4, 1957, into the Low Earth Orbit.
However, the company claims this attempt was successful and can fix the issue with appropriate upper-stage propellant mixtures to achieve the extra velocity.
Rocket Lab’s Electron has over 20 successful launches proving their reliability, and LauncherOne has shown its flexibility by releasing the payload from its Cosmic Girl.

What is a Small Sat Launcher?

According to NASA classification, a small sat launcher (small-lift vehicle) is a class of rocket orbital launch vehicle capable of lifting up to 2000 kg (4,400 lbs.) of payload into low Earth orbit. The Sputnik 1, the first small-lift launch vehicle, was developed by the Soviet Union, and it was successfully launched on October 4, 1957, into the Low Earth Orbit.

There is a growing demand for small sat launchers as they are not only less expensive than their larger counterparts, but they can also meet the requirements of some spacecraft. These lightweight vehicles also take less time to build and launch, making them cost-effective and saving a lot of time.

Upcoming Rockets and Their Unique Features #

Below are some of the upcoming rockets and some of the unique features they present.

Orbex Prime #

Orbex Prime is a small commercial orbital rocket developed by the UK-based aerospace company Orbital Express Launch Ltd.

Prime is a rocket with innovative design. The main structures are made of carbon fire/grapheme composites, and it has a 3D printed engine. This is a unique launch vehicle in the industry as it uses bio-propane, which is expected to reduce 90% emissions versus traditional rocket fuels. The Prime is designed to not leave any post-launch debris either in the ocean or in orbit.

In July 2018, Orbex secured £30 million ($39.6 million) in public and private funding to develop its orbital rocket system named Prime. The European Space Agency (ESA) has also awarded £7.45 million ($8.8 million) contract to Orbex through ESA Boost! Program. Chris Armour, Orbex CEO, says that they are working towards the launch of Prime by the end of 2022 from their new Space Hub Sutherland spaceport in Scotland.

The Prime rocket is a two-stage micro-launcher with a diameter of 1.3 meters and a height of 19 meters and is capable of launching payloads up to 150 kg to Sun-synchronous orbit (SSO).

Skyrora XL #

Skyrora XL designed by the Scotland-based startup Skyrora, headquartered in Edinburgh, is a three-stage orbital launch vehicle. The rocket is in the development phase and is planned to launch from a UK spaceport by the end of 2022. The upper stage of the rocket was successfully tested for a full static fire test.

In April 2021, the company successfully tested the upper stage of the Skyrora XL rocket and completed a static fire test in its engine development complex in Fife.

The Edinburgh Report states, “Skyrorahas received €3 million of co-funding from the European Space Agency (ESA), ensuring that the company can complete at a pace the development of its rocket technology.”

The XL measures 22.7 meters in height and center diameter of 2.2 meters and weighs 56-tonnes and will be capable of carrying 315 kg payload into Polar and SSO orbits.

Small Sat Launchers #

Rocket Labs Electron #

Electron is a two-stage orbit launch vehicle that provides launches for small satellites to Earth orbit. It is developed by the American aerospace company Rocket Lab, with a wholly-owned New Zealand subsidiary.

The Electron has made 21 launches so far and succeeded in 18 attempts and three failures, with the first launch on May 25, 2017, and the latest on July 29, 2021, which was a success. The cost per launch is about $7.5 million.

Electron is partially recoverable, and its main body is constructed with lightweight carbon composite material and is propelled with RP-1/LOX propellant.

The vehicle height is 18 meters and has a diameter of 1.2 meters with a liftoff mass of 13,000 kg. It is designed to carry a payload of 330 kg into SSO.

Virgin Orbits LauncherOne #

LauncherOne is an affordable and flexible launch service built by the US-based company Virgin Orbit for both commercial and government-built satellites.

The LauncherOne is unique as it is carried up into the upper atmosphere and released from a specially adapted Boeing 747-400 called ‘Cosmic Girl’ into orbit. On its second operational mission, June 30, 2021, LauncherOne successfully launched seven CubeSats into orbit. The first attempt on May 25, 2020, failed due to an anomaly shortly after release. The first successful flight was on January 17, 2021.

LauncherOne is a two-stage orbital launch vehicle that measures 21 meters in length to carry smallsat payloads of up to 300 kg (660 lb) into the SSO. The cost per launch is about $12 million.

Astra’s Rocket #

The American launch vehicle company ‘Astray’ was incorporated in October 2016 by Chris Kemp and Adam London.

The California startup has manufactured launch vehicles for both commercial and military customers. The company has named its rocket, ‘Rocket’.

Astray focuses on creating affordable launches with automated rockets that can be shipped anywhere based on customer needs and can be controlled remotely.

On December 15, 2020, Astray launched its second test flight, Rocket 3.2, to space, but the vehicle just missed orbital velocity. However, the company claims this attempt was successful and can fix the issue with appropriate upper-stage propellant mixtures to achieve the extra velocity. Astray hopes to have a successful launch of its Rocket at the earliest.

Rocket 3 is a two-stage launch vehicle and measures 11.6 meters tall, and has a diameter of 1.32 meters has a payload capacity of 25 – 150 kg to low Earth orbit. The cost per launch is about $2.5 million.

Firefly’s Alpha #

Firefly Alpha, developed by the American aerospace company Firefly Aerospace, is a two-stage orbital expendable launch vehicle targeting the commercial smallsat launch market. Alpha is also intended to be a direct competitor to India’s (Polar Satellite Launch Vehicle) PSLV.

Firefly Alpha’s targeted launch in 2020 was derailed partly due to the coronavirus pandemic, but it is confident to launch its Alpha rocket in 2021. The estimated cost per launch is $15 million.

The main body of Alpha is made of advanced carbon fire composites and is fueled with RP-1/LOX propellant; Alpha measures 29 meters tall and 1.82 meters in diameter.

Alpha can launch 600 kg payload to a 500 km sun-synchronous orbit and up to 1000 kg payload to a 200 km low Earth orbit.

ABL Space Systems’s RS1 #

ABL Space Systems was founded in 2017 by former SpaceX and Morgan Stanley employees to develop low-cost launch vehicles focusing on the small satellite industry segment.

RS1 is a two-stage launch vehicle developed by ABL. The launch vehicle would be fueled by kerosene (RP-1) and liquid oxygen (LOX). The first stage will be powered by nine E2 engines, and a single E2 vacuum engine powers the second stage.

The RS1 is 27 meters tall and 1.8 meters in diameter and is capable of carrying a payload of 1,350 kg to the low Earth orbit, 1,000 kg to synchronous sun orbit, 400 kg to geostationary transfer orbit, 250 kg to trains lunar injection, and 125 kg to trains Mars injection.

The RS1 is expected to be launched in 2021. The company has received contracts from the Pentagon’s Defense Innovation Unit (DIU) and Blockhead Martin. It is estimated to be priced at $12 million per launch, a competitive price in its weight class.

Relativity Spaces Terran-1 #

The Terran-1 is a small launch vehicle developed by the American aerospace manufacturing company Relativity Space by combining technologies such as 3D printing, artificial intelligence, and autonomous robotics.

The 3D printed alloy used to build the Terran-1’s engine and structure will reduce the part count by 100 times, thus reducing overall operating cost and increasing reliability.

It is a two-stage launch vehicle powered by nine Aeon 1 engines in the first phase and a single AeonVac engine in the second stage. The rocket would be 35 meters tall and 3 meters in diameter.

The rocket will be capable of carrying a maximum payload of 1,250 kg to 185 km low Earth orbit, a payload of 900 kg to 500 km sun-synchronous orbit (SSO), and a high-altitude payload of 700 kg to 1,200 km SSO.

Although the Terran-1’s debut launch was originally scheduled for 2020, it is now planned for the end of 2021. The cost per launch is expected to be $12 million.

SpaceX’s Falcon-1 #

The Falcon 1 is an expandable orbital launch vehicle developed by the US-based company SpaceX. After three unsuccessful attempts, Melon Musk’s Falcon 1 achieved orbit on September 28, 2008, on its fourth attempt. Its first successful commercial launch was on July 14, 2009, delivering the Malaysian RazakSAT satellite to orbit.

The two-stage small liquid-fueled orbit launch vehicle used LOX/RP-1 for both stages. A single Merlin engine powered the first stage, and the second was powered by a single Kestrel engine.

Falcon 1 was designed to be reusable, minimize price per launch, and increase reliability. The rocket stands 21 meters tall and is 1.7 meters in diameter, and is capable of carrying a payload of 1,000 kg to the low Earth Orbit. The cost per launch is about $7 million.

Summary #

The race for a small lift launch vehicle is stiff, with many aerospace companies joining the competition. The challenge today is to deliver reusable vehicles, thereby reducing production cost and time and reducing rocket debris in orbit. This could also reduce the cost per launch.

Terran-1’s 3D printing technology used is a game-changer as it reduces the number of parts considerably and reducing human interference too. Rocket Lab’s Electron has over 20 successful launches proving their reliability, and LauncherOne has shown its flexibility by releasing the payload from its Cosmic Girl.

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