Rocket Lab is an American/New Zealand company that specializes in small satellite launch vehicles. In August 2021, they announced plans to develop a new medium-lift rocket called Neutron to complement their smaller Electron launcher. Neutron is intended to bridge the capability gap between small launch vehicles like Electron and larger rockets such as Falcon 9, allowing Rocket Lab to competitively launch bigger satellite constellations and cargo missions to the Moon and Mars.
Neutron will utilize a two-stage design and be powered by eight 3D printed Rutherford engines during launch. The Rutherford engine uses liquid oxygen and RP-1 propellant and can throttle between 150,000 and 170,000 pounds of thrust. For comparison, the single Rutherford engine on Electron produces just 17,000 pounds of thrust. Neutron’s stages will be able to be reused up to ten times each via vertical takeoffs and landings. Rocket Lab plans to recover the engines as well using helicopter capture soon after stage separation.
The core stage of Neutron will stand around 95 feet tall with a diameter of 7 feet. Its eight Rutherford engines will produce a total of over 2.5 million pounds of thrust at liftoff, which is more comparable to launch vehicles in the Delta IV and Falcon 9 class. The second stage will also use Rutherford engines and stand around 30 feet tall. Neutron will be able to launch over 8,000 kg to low Earth orbit, over 2,200 kg to lunar orbit, and over 1,500 kg for trans-Mars injection. This exceeds Electron’s capability about eightfold.
For comparison purposes, Rocket Lab bills Neutron as having three times the lift of Electron but at one-third the cost of similarly-class vehicles. Due to its smart architecture and use of 3D printing for engine components, they expect to build and launch Neutrons faster and at a lower unit cost than competitors. The expected list price per launch is around $15 million, making it very competitive in the medium-lift market currently dominated by SpaceX’s Falcon 9.
Construction and testing of Neutron is expected to occur in multiple phases over the next few years. Preliminary design work is already underway and expected to continue through 2022. Full-scale production of the Rutherford engine is planned to start by 2023. An Orbital Launch Complex 2 will be constructed in Virginia for Neutron launches by 2024 and debut missions anticipated before the end of that year. Rocket Lab hopes to conduct the first orbital test launch of Neutron by the end of 2024 or early 2025.
Following the test program, Rocket Lab plans to rapidly increase Neutron production and launch rates. Their goal is to reach a production cadence of conducting two Neutron launches per month by 2027. This launch frequency is expected to allow cost-effective deployment of large constellations and opening regular dedicated rideshare opportunities for smaller satellites needing a ride to space. With multi-location production sites, they eventually hope to scale Neutron production up to over 50 units per year.
The development and operation of Neutron is a major strategic move that could transform Rocket Lab into a leader for medium-lift launches globally. It will allow them to fulfill larger national security, Moon/Mars cargo delivery, and megaconstellation deployment contracts that have so far gone mainly to large players like SpaceX, ULA, and Arianespace. Early customer interest for dedicated and rideshare missions on the Neutron has already been strong despite the program only just being announced. If development proceeds smoothly, Neutron could cement Rocket Lab’s position as one of the world’s go-to launch providers through the 2020s and beyond. Being able to launch larger and more complex payloads at lower costs per kilogram than competing vehicles will open many new possibilities for both government and commercial satellite operators.
Rocket Lab’s Neutron launch vehicle aims to disrupt the medium-lift launch market in the coming years with its innovative 3D printed Rutherford engine technology, frequent low-cost reusability, and high production capabilities. With an anticipated first launch around 2024-2025, Neutron has the potential to become a workhorse for cargo missions beyond LEO and large constellation deployment if it matches Rocket Lab’s ambitious schedule and performance goals. Its success would cement them as a major player in global spacelift and support further expansion of the new space economy.