With Rocket Lab’s Daring Midair Catch, Reusable Rockets Go Mainstream

May 12, 2022 by Tom Nardi 34 Comments

We’ve all marveled at the videos of SpaceX rockets returning to their point of origin and landing on their spindly deployable legs, looking for all the world like something pulled from a 1950s science fiction film. On countless occasions founder Elon Musk and president Gwynne Shotwell have extolled the virtues of reusable rockets, such as lower operating cost and the higher reliability that comes with each booster having a flight heritage. At this point, even NASA feels confident enough to fly their missions and astronauts on reused SpaceX hardware.

Even so, SpaceX’s reusability program has remained an outlier, as all other launch providers have stayed the course and continue to offer only expendable booster rockets. Competitors such as United Launch Alliance and Blue Origin have teased varying degrees of reusability for their future vehicles, but to date have nothing to show for it beyond some flashy computer-generated imagery. All the while SpaceX continues to streamline their process, reducing turnaround time and refurbishment costs with each successful reuse of a Falcon 9 booster.

But that changed earlier this month, when a helicopter successfully caught one of Rocket Lab’s Electron boosters in midair as it fell back down to Earth under a parachute. While calling the two companies outright competitors might be a stretch given the relative sizes and capabilities of their boosters, SpaceX finally has a sparing partner when it comes to the science of reusability. The Falcon 9 has already smashed the Space Shuttle’s record turnaround time, but perhaps Rocket Lab will be the first to achieve Elon Musk’s stated goal of re-flying a rocket within 24 hours of its recovery.

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Mothballing Rosalind: How To Put A Space Mission In Storage

April 11, 2022 by Dan Maloney 13 Comments

In planetary exploration circles, Mars has quite a bad reputation. The Red Planet has a habit of eating spacecraft sent there to explore it, to the degree that nearly half of the missions we’ve thrown at it have failed in one way or another. The “Mars Curse” manifests itself most spectacularly when landers fail to negotiate the terminal descent and new billion-dollar craters appear on the Martian regolith, while some missions meet their doom en route to the planet, and an unlucky few have even blown up on the launchpad.

But the latest example of the Mars Curse, the recent cancellation of the second half of the ExoMars mission, represents a new and depressing failure mode: war — specifically the Russian invasion of Ukraine. The international outrage over the aggression resulted in economic sanctions and diplomatic isolation of Russia, which retaliated by ending its partnership with the European Space Agency (ESA), depriving the mission of its launch vehicle and dooming the mission that would have landed the rover Rosalind Franklin on Oxia Planum near the Martian Equator in 2023.

While there’s still a chance that administrators and diplomats will work things out, chances are slim that it will be in time for the narrow launch window that the mission was shooting for in September of 2022. That means the Rosalind Franklin, along with all the other flight hardware that was nearly ready to launch, will have to be put in storage at least until the next launch window opens in 2024. That begs the question: how does one put a complex spacecraft into storage? And could such mothballing have unintended consequences for the mission when it eventually does fly?

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Astra’s Frugal Design Leads To Latest Unusual Failure

February 23, 2022 by Tom Nardi 36 Comments

We’ve all heard it said, and it bears repeating: getting to space is hard. But it actually gets even harder the smaller your booster is. That’s because the structure, engines, avionics, and useful payload of a rocket only make up a tiny portion of its liftoff mass, while the rest is dedicated to the propellant it must expend to reach orbital velocity. That’s why a Falcon 9 tipping the scales at 549,054 kilograms (1,207,920 pounds) can only loft a payload of 22,800 kg (50,265 lb) — roughly 4% of its takeoff weight.

As you might imagine, there’s a lower limit where there simply isn’t enough mass in the equation for the hardware necessary to build a fully functional rocket. But where is that limit? That’s precisely what aerospace newcomer Astra is trying to find out. Their Rocket 3 is among the smallest orbital boosters to ever fly, closer in size and mass to the German V2 of World War II than the towering vehicles being built by SpaceX or Blue Origin. Even the Rocket Lab Electron, itself an exceptionally svelte rocket, is considerably larger.

The reason they’re trying to build such a small rocket is of course very simple: smaller means cheaper. Assuming you’ve got a payload light and compact enough to fit on their launcher, Astra says they can put it into orbit for roughly $2.5 million USD; less than half the cost of a dedicated flight aboard Rocket Lab’s Electron, and competitive with SpaceX’s “rideshare” program. Such a low ticket price would have been unfathomable a decade ago, and promises to shake up an already highly competitive commercial launch market. But naturally, Astra has to get the thing flying reliably before we can celebrate this new spaceflight milestone.

Their latest mission ended in a total loss of the vehicle and payload when the upper stage tumbled out of control roughly three minutes after an otherwise perfect liftoff from Cape Canaveral Space Force Station in Florida. Such issues aren’t uncommon for a new orbital booster, and few rockets in history have entered regular service without a lost payload or two on the books. But this failure, broadcast live over the Internet, was something quite unusual: because of the unconventional design of Astra’s diminutive rocket, the upper stage appeared to get stuck inside the booster after the payload fairing failed to open fully.

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Homemade Toy Wind Tunnel Blows (Really Well)

February 18, 2022 by Adam Zeloof 6 Comments

Sometimes a kid wakes up on Christmas morning and runs downstairs, only hoping to see one thing: a shiny new wind tunnel. This past December, that’s exactly what [SparksAndCode]’s son found ~~under~~ beside the tree, complete with a bag of scarves, ping-pong balls, and other fun things to launch through it (in the name of physics, of course).

The real story here starts about a week before Christmas, when [SparksAndCode]’s son was enthralled by a similar device at a science museum. At his wife’s suggestion, [SparksAndCode] got to work designing a and building a wind tunnel with hardware-store parts, his deadline looming ahead. The basic structure of the tunnel is three rods which support plywood collars. The walls are formed by plastic sheets rolled inside the collars to make a tube. Underneath, a Harbor Freight fan supplies a nice, steady stream of air for endless entertainment.

After finding a few bugs during his son’s initial beta testing on Christmas morning, [SparksAndCode] brought the wind tunnel back into the shop for a few tweaks and upgrades, including a mesh cover on the air intake to stop things from getting sucked into the fan. The final result was a very functional (and fun!) column of air. Looking for even more function (but not necessarily less fun)? We’ve got you covered too with this home-built research wind tunnel from a few years back.

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NASA Taps Lockheed To Bring Back A Piece Of Mars

February 14, 2022 by Tom Nardi 36 Comments

Since NASA’s Mariner spacecraft made the first up-close observations of Mars in 1964, humanity has lobbed a long line of orbiters, landers, and rovers towards the Red Planet. Of course, it hasn’t all been smooth sailing. History, to say nothing of the planet’s surface, is littered with Martian missions that didn’t quite make the grade. But we’ve steadily been getting better, and have even started to push the envelope of what’s possible with interplanetary robotics through ambitious craft like the Ingenuity helicopter.

Yet, after nearly 60 years of studying our frigid neighbor, all we have to show for our work boils down to so many 1s and 0s. That’s not to say the data we’ve collected, both from orbit and on the surface, hasn’t been extremely valuable. But scientists on Earth could do more with a single Martian rock than any robotic rover could ever hope to accomplish. Even still, not so much as a grain of sand has ever been returned from the planet’s dusty surface.

But if everything goes according to plan, that’s about to change. Within the next decade, NASA and the European Space Agency (ESA) hope to bring the first samples of Martian rocks, soil, and atmospheric gases back to Earth using a series of robotic vehicles. While it’s still unclear when terrestrial scientists should expect delivery of this interplanetary bounty, the first stage of the program is already well underway. The Perseverance rover has started collecting samples and storing them in special tubes for their eventual trip back to Earth. By 2028, another rover will be deployed to collect these samples and load them into a miniature rocket for their trip to space.

Launching the Mars Ascent Vehicle (MAV).

Just last week NASA decided to award the nearly $200 million contract to build that rocket, known officially as the Mars Ascent Vehicle (MAV), to aerospace giant Lockheed Martin. The MAV will not only make history as the first rocket to lift off from a celestial body other than the Earth, but it’s arguably the most critical component of the sample return mission; as any failure during launch will mean the irrevocable loss of all the samples painstakingly recovered by Perseverance over the previous seven years.

To say this mission constitutes a considerable technical challenge would be an understatement. Not only has humanity never flown a rocket on another planet, but we’ve never even attempted it. No matter what the outcome, once the MAV points its nose to the sky and lights its engines, history is going to be made. But while it will be the first vehicle to make the attempt, engineers and scientists have been floating plans for a potential Martian sample return mission for decades. Continue reading “NASA Taps Lockheed To Bring Back A Piece Of Mars” →

How Can 335 Horses Weigh 63 Pounds?

February 9, 2022 by Al Williams 110 Comments

Koenigsegg, the Swedish car company, has a history of unusual engineering. The latest innovation is an electric motor developed for its Gemera hybrid vehicle. The relatively tiny motor weighs 63 pounds and develops 335 horsepower and 443 lb-ft of torque. Dubbed the Quark, the motor uses both radial and axial flux designs to achieve these impressive numbers.

There is a catch, of course. Like most EV motors, those numbers are not sustainable. The company claims the motor can output peak power for 20 seconds and then drops to 134 horsepower/184 lb-ft of torque. The Gemera can supplement, of course, with its internal combustion engine — a 3 cylinder design.

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Working Model Reveals Amazing Engineering Of Webb’s Mirror Actuators

February 8, 2022 by Dan Maloney 29 Comments

We end up covering a lot of space topics here on Hackaday, not because we’re huge space nerds — spoiler alert: we are — but because when you’ve got an effectively unlimited budget and a remit to make something that cannot fail, awe-inspiring engineering is often the result. The mirror actuators on the James Webb Space Telescope are a perfect example of this extreme engineering, and to understand how they work a little better, [Zachary Tong] built a working model of these amazing machines.

The main mirror of the JWST is made of 18 separate hexagonal sections, the position of each which must be finely tuned to make a perfect reflector. Each mirror has seven actuators that move it through seven degrees of freedom — the usual six that a Stewart platform mechanism provides, plus the ability to deform the mirror’s curvature slightly. [Zach]’s model actuator is reverse-engineered from public information (PDF) made available by the mirror contractor, Ball Aerospace. While the OEM part is made from the usual space-rated alloys and materials, the model is 3D printed and powered by a cheap stepper motor.

That simplicity belies the ingenious mechanism revealed by the model. The actuators allow for both coarse and fine adjustments over a wide range of travel. A clever tumbler mechanism means that only one motor is needed for both fine and coarse adjustments, and a flexure mechanism is used to make the fine adjustments even finer — a step size of only 8 nanometers!

Hats off to [Zach] for digging into this for us, and for making all his files available in case you want to print your own. You may not be building a space observatory anytime soon, but there’s plenty about these mechanisms that can inform your designs.

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