Tag: New Glenn

Blue Origin moves first stage of its New Glenn rocket from factory to launchpad hanger

10:08 am

In what might be the first step in assemblying Blue Origin’s New Glenn rocket for the first time (followed by a launch), the company yesterday transported the rocket’s first stage from its factory to its launchpad hanger.

Transported by a series of multiwheeled carriages and an arching structure, the 189-foot-tall first stage for what will be a 320-foot-tall rocket when fully assembled traveled horizontally on a 22-mile trip from the New Glenn factory in Merritt Island through Kennedy Space Center over to Cape Canaveral Space Force Station where Blue Origin has a hangar and launch pad at Launch Complex 36.

Jeff Bezos has said the company plans that first launch before the end of this year, though the company has been making this same promise now for the last three years, and is years behind schedule. What makes this promise different however is that this time we are seeing actual hardware moving towards the launchpad.

The article also gives a rough update on the company’s effort to manufacture the many BE-4 rocket engines needed for New Glenn (7) and ULA’s Vulcan rocket (2). The two engines for the next Vulcan launch in April are presently undergoing final testing at Blue Origin’s test facility in Texas, and the company says it is about to ramp up production. It thus appears that getting enough engines built is still the main obstacle to launch. We shall finally know later this year if Blue Origin has solved this problem.

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Amazon files to have shareholder lawsuit dismissed

9:15 am

On December 11, 2023 Amazon requested dismissal of a shareholder lawsuit against it for acting in bad faith by excluding SpaceX in its initial launch contracts with ULA, Arianespace, and Blue Origin to put its Kuiper constellation of satellites into orbit.

The lawsuit claimed that the board performed little diligence on the proposed contracts to launch the 3,236-satellite constellation with the Ariane 6, New Glenn and Vulcan Centaur rockets. The combined contracts were, it stated, the second largest capital expenditure in Amazon’s history at the time, trailing only its $13.7 billion acquisition of grocer Whole Foods.

The lawsuit stated that the board and its audit committee spent “barely an hour” reviewing those contracts, including those that would go to Blue Origin and ULA. Blue Origin is owned by Amazon founder and former chief executive Jeff Bezos, while ULA has a contract with Blue Origin to use BE-4 engines on its Vulcan rocket. The suit estimated that nearly 45% of the value of the contracts goes to Blue Origin either directly or through the BE-4 engine contract with ULA.

Amazon’s call for dismissal disputes these claims, stating that the board spent far more time on the issue, and then documents this. Interestingly, it makes no mention of the recent additional launch contract Amazon signed with SpaceX on December 3, 2023, but it is obvious that this filing was timed to occur afterward in order to strengthen Amazon’s case.

Amazon’s response (available at the link above) is heavily redacted, so some of the company’s claims are difficult to assess. For example, if the board did consider the issue of launch contractors properly, the subject of using SpaceX should have come up and been discussed at length. The redactions make it impossible to determine if this was so. If anything, what can be read suggests SpaceX was dismissed as an option far too quickly.

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A tour of Blue Origin’s Huntsville Machine Shop & Manufacturing Facility

9:36 pm

Video below, which is heavily focused on machining and machine shop work. The facility, the Machine Shop & Manufacturing Facility in Huntsville, appears to build the BE-3U engine (to be used for the New Glenn upper stage), though I thought some of the engines shown could be BE-4’s. I hope my readers can help clarify this.

While this video actually reveals very little solid information, one important fact was disclosed near the end, when the tour reached the final engine assembly point. There the Blue Origin employee mentioned that they are assembling three engines at this facility. Considering facility’s size and the number of engines that will be needed once New Glenn begins flying, I was not impressed. Does it really take this much space and equipment to only build three rocket engines? Am I wrong?

Hat tip to reader John Harman, who is himself the owner of an aerospace manufacturing company.

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Amazon signs launch contract with SpaceX

9:32 am

Amazon on December 1, 2023 announced it has signed a three-launch contract with SpaceX to place its Kuiper satellites into orbit, supplementing the launch contracts it presently has with ULA, Arianespace, and Blue Origin. From the Amazon press release:

SpaceX’s Falcon 9 is a reusable, two-stage launch vehicle designed for the reliable and safe transport of people and payloads into Earth orbit and beyond, and it has completed more than 270 successful launches to date. Project Kuiper has contracted three Falcon 9 launches, and these missions are targeted to lift off beginning in mid-2025.

In 2022 Amazon had signed contracts with the other three launch companies, with ULA getting 38 Vulcan launches (in addition to 9 already signed for its Atlas-5), Arianespace getting 18 Ariane-6 launches, and Blue Origin getting 12 New Glenn launches.

The problem however is that, except for the Atlas-5, none of these rockets has yet completed its first flight. Since Amazon’s FCC license requires it to get half of its constellation of 3,200+ satellites into orbit by 2026 or face penalties, the uncertainty of these rockets has probably forced Amazon management to consider SpaceX, despite likely hostility to such a deal from Jeff Bezos (owner of Blue Origin and founder of Amazon).

Amazon management also probably decided to sign this deal because of a lawsuit filed in September 2023 by company stockholders, accusing the management of neglience because it never even considered SpaceX in earlier contract negotiations while giving favoritism to Bezos’s company Blue Origin. At that time Amazon had already paid these launch companies about $1.7 billion, with Blue Origin getting $585 million, though not one rocket has yet launched, with Blue Origin showing no evidence that a launch coming anytime soon.

The impression of a conflict of interest by Amazon’s board of directors appeared very obvious. This new SpaceX contract weakens that accusation.

More important the deal will help Amazon actually get its satellites into orbit. It appears that reality is finally biting at Amazon, and its management has realized that the three companies they have been relying on might not be up to the job (especially Blue Origin).

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Update on Blue Origin activity at Cape Canaveral

9:16 am

Link here. Much of the activity the article describes has to do with preparing for a first launch of Blue Origin’s New Glenn rocket, suggesting that it might finally take place in 2024 as presently planned.

In fact, the activity also suggests that the company intends to attempt to recover its first stage from a landing ship in the ocean on that first flight.

In early October, a large Liebherr mobile crane was delivered to Port Canaveral to support Blue Origin’s continuously growing presence on the Space Coast. Once New Glenn begins flying, this crane will assist recovery operations by lifting the 57.5-meter-tall first stage from the landing vessel and onto shore.

More recently on Nov. 27, a large jig on a barge was towed into Port Canaveral and proceeded to be offloaded by Blue Origin’s new crane. This custom-made structure appears to be a stand to support New Glenn first stages after being offloaded from its landing vessel. Various work platforms will allow crews to inspect the boosters in different locations before the booster itself is transported back to the factory, or the future refurbishment facility which is still yet to be built.

It also appears the company has built a full scale test version of New Glenn to allow testing of all operations prior to launch.

Keep your fingers crossed. With former CEO Bob Smith gone, Blue Origin might finally be coming back alive at last.

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Amazon’s first two Kuiper satellites in orbit worked exactly as planned

2:55 pm

Amazon announced today that its first two Kuiper satellites, launched into orbit by ULA’s Atlas-5 rocket on October 6, 2023, have worked exactly as planned, thus allowing the company to begin building operational satellites.

With the prototypes’ testing in space now complete, Badyal said Amazon plans to begin building the first production Kuiper satellites in December and launch the first satellites for its network in the “latter part of the first half” of 2024. Badyal emphasized that Amazon wasn’t sure what performance to expect from the prototype satellites, since “you don’t know how well it’s going to work in space.”

“They’re working brilliantly,” Badyal said.

The need of Amazon to start launching lots of satellites next year — in order to meet its FCC license requirements to put half of its 3,000+ constellation in orbit by 2026 — puts great pressure on ULA, Blue Origin, and Arianespace to get their new but as yet unlaunchd rockets operating. All three have big launch contracts with Amazon, but none presently appear to have the capability to meet the demands of those contracts.

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Bob Smith out at Blue Origin

8:03 pm

Though this change probably comes four years late, the CEO of Blue Origin, Bob Smith, announced today that he is resigning from the company, effective at the end of the year.

The company’s incredibly slow implementation of all of its projects, which begun when Smith took over in 2017, has made it something of joke punchline in the space business. Suborbital test flights of its New Shepard spacecraft went from almost monthly test flights to none for years. Its orbital New Glenn rocket is four years behind schedule, and it is still doubtful it will fly next year. And the company’s BE-4 rocket engine was also years behind schedule and even now has caused enormous delays for its one outside customer, ULA, delaying the launch of its Vulcan rocket by at least four years. As noted at the link:

Smith brought a traditional aerospace mindset into a company that had hitherto been guided by a new space vision, leading to a high turnover rate. And Blue Origin remains significantly underwater, financially. It is likely that Bezos is still providing about $2 billion a year to support the company’s cash needs.

Crucially, as Blue Origin meandered under Smith’s tenure, SpaceX soared, launching hundreds of rockets and thousands of satellites. Smith, clearly, was not the leader Blue Origin needed to make the company more competitive with SpaceX in launch and other spaceflight activities. It became something of a parlor game in the space industry to guess when Bezos would finally get around to firing Smith.

Smith will be replaced by Dave Limp, who had been Amazon’s VP for devices and services until last month. Whether he can get this company moving again is still an unknown, considering he was also involved in launching Amazon’s Kuiper satellite constellation, the development of which has been as slow and uninspiring as all of Blue Origin’s projects.

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Update on Blue Origin’s New Glenn

10:04 am

Link here. Based on this detailed update, the long delayed launch of Blue Origin’s orbital New Glenn rocket appears to finally be visible on the distant horizon.

Most of the work described involves building supporting facilities, such as a new building for refurbishing rockets after launch. However, this quote suggests the company might finally be getting close to doing something real:

During a panel at the World Satellite Business Week, Blue Origin’s Jarrett Jones stated Blue Origin has four boosters in various stages of production, and testing is going well.

In addition to the production of New Glenn, Blue Origin has continued to prepare LC-36 [the launchpad] to support the testing of the hardware currently being manufactured. In recent months, Blue Origin has conducted a number of tests with both the main transporter erector, which will be used to support a fully stacked New Glenn, as well as a smaller transporter erector, which appears to be used to test New Glenn’s second-stage on the launch pad. A second-stage simulator has already been observed on this transporter erector.

Though encouraging, the article at the link still left me with a feeling that a lot of work is being done on everything but the rocket itself. Hopefully this feeling will dissipate soon with the appearance of that first rocket on the launchpad. Right now Blue Origin officials have said they are aiming for that first launch next year, but they have made that same promise now for three straight years.

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Update on the status of Vulcan, Ariane-6, and New Glenn

9:48 am

Link here. This excellent article is focused on whether these three new rockets, none of which has yet completed its first test flight, will be able to meet their launch contract obligations with Amazon, which needs to launch at least 1,600 satellites of its Kuiper broadband constellation by July 2026 to meet its FCC license requirements. Those requirements also obligate Amazon to have the full constellation of about 3,200 satellites in orbit by July 2029.

The launch contracts to these three untried rockets was the largest such contract ever issued, involving 83 launches and billions of dollars.

To sum up where things stand in terms of the first test launch of each rocket:
» Read more

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Blue Origin BE-4 rocket engine explodes during test

4:03 pm

This failure has been kept very quiet, but on June 11, 2023 during a static fire engine test of a Blue Origin BE-4 rocket engine, it exploded 10 seconds into the test.

During a firing on June 30 at a West Texas facility of Jeff Bezos’ space company, a BE-4 engine detonated about 10 seconds into the test, according to several people familiar with the matter. Those people described having seen video of a dramatic explosion that destroyed the engine and heavily damaged the test stand infrastructure. The people spoke to CNBC on the condition of anonymity to discuss nonpublic matters.

The engine that exploded was expected to finish testing in July. It was then scheduled to ship to Blue Origin’s customer United Launch Alliance for use on ULA’s second Vulcan rocket launch, those people said.

The story is based on anonymous sources, but if true it means another serious setback for both ULA’s Vulcan rocket and Blue Origin’s New Glenn rocket. Vulcan has the BE-4 engines it needs to launch its first Vulcan, but it might feel forced to delay that launch until it receives the analysis of this failed test.

It also means that even after more than a decade of development, Blue Origin has still not worked out all the kinks in its BE-4 engine. This inability does not speak well for the company. Are they not testing enough? Are they not questioning their designs enough?

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Blue Origin negotiating with India to use its rockets and capsule for Orbital Reef space station

10:20 am

According to the head of India’s space agency ISRO, he has been in discussions with Blue Origin about using different versions of that nation’s largest rocket (dubbed LVM-3 or GSLV-Mk3 depending on configuration) and its manned capsule (still under development) for eventually ferrying crew and cargo to Blue Origin’s proposed Orbital Reef space station.

Somanath said: “We are exploring … In fact, we’ve already discussed it with Blue Origin and they are very keen to consider this option of LVM-3 becoming a crew capsule mission to service the Orbital Reef. It is a possibility and we are engaging through IN-SPACe (Indian National Space Promotion and Authorisation Centre).”

On the challenge of integrating a docking system that is compatible, he said standard docking systems are in the public domain. “…Whoever can design a docking system that matches with the US design and standard, can be used. However, we will still need to have agreements with agencies to try it out given that there are multiple interfaces — electrical, mechanical and so on. It is not just one document, we will need to work with them to develop it. We will do that.

It appears Somanath has also had discussions with NASA about also providing the same service to ISS.

An Orbital Reef deal however suggests something very disturbing about Blue Origin. The plan had been to use Blue Origin’s New Glenn orbital rocket (also still under development but years behind schedule) to launch crew and cargo capsules to the station. That in fact is supposed to be Blue Origin’s main technical contribution to the station. Why would the company then look to India for such capability, unless it recognizes that there are more problems with New Glenn that it has not revealed?

It is also possible that Jeff Bezos is simply expressing his leftwing globalist agenda with these negotiations. Or it could mean some combination of both. This situation bears watching.

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Viasat drops launch contract with Ariane-6

9:03 am

With SpaceX’s Falcon Heavy having just completed the first of three launches for Viasat’s new geosynchronous constellation of communication satellites, the satellite company has announced that it is cancelling its launch contract with Ariane-6 for the third launch.

The decision means the launch contract is up for grabs for the third ViaSat 3 internet satellite, the last of a three-satellite constellation Viasat is deploying to provide global broadband connectivity from space.

Viasat announced in 2018 it selected SpaceX, United Launch Alliance, and Arianespace to each launch one ViaSat 3 satellite, awarding launch contracts to three industry leaders.

The ULA launch, on its Atlas-5 rocket, is still scheduled for either late this year or early next.

The development of Ariane-6 however is years behind schedule. Furthermore, Arianespace has given priority on Ariane-6 to all of the ESA launches that formerly were going to be launched on Russian Soyuz rockets, further delaying Viasat’s launch.

For Viasat, the delays have become unacceptable, and it has now opened that third launch to bidding. Though both ULA’s Vulcan and Blue Origin’s New Glenn rockets could do the job, neither is operational either. It appears SpaceX’s Falcon Heavy is the only rocket available and is therefore almost certain to get the contract, a conclusion further confirmed by the timing of this announcement, just prior to that successful Falcon Heavy launch.

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NASA awards launch contract to Blue Origin’s unlaunched New Glenn rocket

9:09 am

NASA yesterday awarded Blue Origin the launch contract for its smallsat ESCAPADE Mars orbiter mission, set to launch in late 2024.

ESCAPADE will launch on Blue Origin’s New Glenn rocket from Space Launch Complex-36 at Cape Canaveral Space Force Station in Florida. Launch is targeted for late 2024. Blue Origin is one of 13 companies NASA selected for VADR contracts in 2022. NASA’s Launch Services Program, based at the agency’s Kennedy Space Center in Florida, manages the VADR contracts. As part of VADR, the fixed-price indefinite-delivery/indefinite-quantity contracts have a five-year ordering period with a maximum total value of $300 million across all contracts.

NASA’s VADR program is designed to give contracts to higher risk contractors to help those launch companies develop their rockets. Since New Glenn is years behind schedule and as-yet unlaunched, this contract is an attempt to help change that. Note however that it is fixed price, and does not set a deadline for Blue Origin to launch.

ESCAPADE will actually be two orbiters designed to study the faint artifacts of Mars’ magnetosphere left over from its past.

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Blue Origin’s BE-4 rocket engine experiences more delays

9:27 am

Capitalism in space: Though Blue Origin appears only a few weeks from delivering its first flightworthy BE-4 rocket engine to ULA for use in that company’s new not-yet-launched Vulcan rocket, the second flightworthy engine is further delayed due to technical problems discovered when static fire testing began.

Sources told Ars that the first engine was put onto the test stand in Texas early in August, but almost as soon as work began to hot-fire the powerful engine, an issue was discovered with the engine build. This necessitated a shipment back to Blue Origin’s factory in mid-August, as the company’s test stands in Texas do not allow for more than minor work.

As a result of this technical issue, ULA now appears likely to get one flight engine this month, but it probably will not receive the other one for installation onto the Vulcan rocket before mid-October, assuming a clean battery of tests in Texas.

This issue almost certainly means that Vulcan will not attempt its first launch this year. The rocket is thus more than three years behind schedule.

The problems outlined here however are far greater than simply the technical issues with this one engine. First, Blue Origin’s pace of operations continues to be far too leisurely. Nothing the company has done since 2017 has proceeded with any sense of urgency, and thus neither ULA nor Blue Origin have been able to launch their rockets.

Second, and far more important, Blue Origin is supposed to be manufacturing the BE-4 for two rockets, both Vulcan and its own New Glenn. Neither rocket will be reusable to begin with, which means the number of needed engines required at first will be high. For example, ULA has contracts to launch Vulcan twice almost immediately, with the need to follow these with several military launches. Each launch will require two BE-4 engines, so Blue Origin at a minimum needs to manufacture four engines, probably more, just to fulfill its obligations to ULA. To supply its own New Glenn rocket, it needs seven BE-4 engines for each launch, with the company having four launches on its manifest for 2023.

All told, Blue Origin thus has to deliver, at a minimum, 32 engines in 2023 alone, to meet its contractual obligations. And since the rockets and engines will be untested, expect at least one or two launch failures that will further increase the need for more engines.

Yet, there is no sign that Blue Origin has figured out how to manufacture these engines on an assembly line basis. Even if it gets these two engines delivered soon, it is unclear it can produce a lot of flightworthy engines fast enough to meet this launch schedule. Expect therefore that both rockets will continue to experience launch delays that could stretch out years.

Meanwhile, a plethora of new rocket companies have been appearing, all aiming eventually to compete with Blue Origin and ULA. If Blue Origin doesn’t get a move on, these new companies will soon be in a position to replace both it and ULA, entirely.

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August 29, 2022 Quick space links

2:19 pm

Courtesy of BtB’s stringer Jay:

As I’ve said numerous times, I’ll believe this engine is a flight engine when I see it in flight.

The link goes to the research paper from the Beijing Institute of Space Mechanics and Electricity, which is in Chinese except for the abstract. This tweet highlights the “leg deploying test and full-scale landing impact experiment” from that paper.

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Blue Origin abandons plans to land New Glenn first stages on purchased cargo ship

9:31 am

Capitalism in space: This week it was revealed that Blue Origin has abandoned its plan to use a purchased and refurbished cargo ship as an ocean landing platform for the first stages of its New Glenn rocket.

The company had bought the ship in 2018, when it thought New Glenn would be flying by 2020, and planned to reconfigure it by covering it with a giant landing pad. It appears the company abandoned that plan because of cost. What it plans to do instead to provide New Glenn first stages a place to land remains unclear.

Some historical details that provide some context and might explain the change in plans. In 2016 Blue Origin was launching test flights of its New Shepard suborbital craft on almost a monthly basis. It appears to have an aggressive attitude towards development, with New Glenn aiming for a 2020 launch.

In 2017 Jeff Bezos hired Bob Smith to take over as Blue Origin’s CEO. At that point development slowed to a crawl. For the next four years New Shepard test flights dropped to about one per year. Also at that time development of the BE-4 rocket engine needed for both New Glenn and ULA’s Vulcan rocket also slowed to a crawl, apparently because the company’s management would not commit funds to buy extra engines for testing.

In 2018 Blue Origin signed a deal with the Air Force, thus delaying New Glenn’s first launch by a year. The deal appeared to stem from a desire of Blue Origin management to get government contracts and money first rather than committing any company money to development, the approach used by older big space companies for decades. While it reduces risk, this approach also makes the government a partner in development, which has historically slowed all development while significantly raising costs.

That same year it bought this ship as the rocket’s landing pad, though relatively little work is done on it for years.

In 2021 Jeff Bezos stepped down as Amazon CEO to focus more time on Blue Origin. Suddenly, New Shepard ups its launch rate, and finally starts flying passengers. At the same time, the testing of the BE-4 engine appears to accelerate.

Now Blue Origin is abandoning this ship that was purchased after Bob Smith took over.

Does one get the feeling that Bezos might have finally realized that the management under Smith was not very effective? Smith is still Blue Origin’s CEO, but one wonders how long this will last.

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Blue Origin’s BE-4 engine set for “commissioning” tests

1:29 pm

Capitalism in space: According to a tweet from Blue Origin on June 21, 2022, engineers have finally installed a flight-worthy engine on the test stand in Huntsville for static fire “commissioning” tests.

This is an engine that was supposed to be delivered to ULA for its new Vulcan rocket more than two years ago. With final engine tests only beginning now, it likely means the engine will not be delivered for at least several more months.

ULA will then have to install it in the rocket, and do its own fueling and static fire tests. All this suggests that a Vulcan launch before the end of this year is almost impossible.

When Blue Origin’s own New Glenn rocket will fly using the BE-4 is utterly unknown. ULA at least has built a full-scale test version of Vulcan and done launch countdown rehearsals in order to iron out issues with its launchpad and ground systems. Blue Origin has done none of this.

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Blue Origin rethinking plans for landing its first stage?

8:57 am

Capitalism in space: Though the company has said little, according to this local Florida newspaper Blue Origin is rethinking its plans to use the cargo ship Jacklyn as a platform for landing its New Glenn first stages in the ocean.

The 600-foot former cargo ship has been docked at the Port of Pensacola since 2018 and undergoing a retrofit by the Pensacola company Offshore Inland to enable the ship to serve as a landing platform for the first stage of Blue Origin’s New Glenn rocket.

When contacted by the News Journal to ask if the retrofit project had been canceled, a Blue Origin spokesperson responded that no final decision had been made yet.

The company is looking at “different options” for recovery vessels that give the best chance for mission success while also being safe and cost-effective, the spokesperson said.

This could be good news or bad news. Either it means Blue Origin is now getting close to finally launching New Glenn, which is three years behind schedule, or it has suddenly realized that using this cargo ship never made sense, and it is scrambling to find a solution at this late date.

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Amazon announces launch agreements with Blue Origin, Arianespace, and ULA

9:42 am

Capitalism in space: Amazon today announced major multi-launch agreements with Blue Origin, Arianespace, and ULA to launch its 3,000+ Kuiper satellite constellation.

According to the press release, ULA won 38 launches using its new Vulcan-Centaur rocket (not yet flown), Arianespace won 18 launches using its new Ariane-6 rocket (not yet flown), and Blue Origin won 12 launches using its new New Glenn rocket (not yet flown), with an option for 15 more. The ULA deal is in addition to a previous launch contract of nine launches using the Atlas-5 rocket.

In addition, Amazon hopes to launch two prototype satellites later this year using ABL’s smallsat RS1 rocket (not yet flown).

Overall, this Amazon launch announcement might be the largest launch contract deal ever. However, the company’s reliance on unproven rockets means it will also likely face some delays and failures in its early stages. That the press release makes no mention of any schedule for launches illustrates this fact starkly. All four rockets have already seen major delays. with the three biggest (Vulcan-Centaur, New Glenn, Ariane 6) now more than two years behind schedule, and the likelihood of their first launch occurring in 2022 increasingly unlikely.

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Blue Origin delays 1st New Glenn launch again

9:10 am

Capitalism in space: At a conference earlier this week Blue Origin officials confirmed that the first test flight of its orbital New Glenn rocket will not occur in ’22, but will be delayed again, into ’23.

New Glenn was originally supposed to launch in 2020, and has been delayed repeatedly since then, first because of new requirements imposed by the military and then because of delays in getting Blue Origin’s BE-4 rocket engine operational.

Though ULA is still aiming to launch its Vulcan rocket using the BE-4 in 2022, expect it to eventually recognize reality and delay also to ’23. That rocket was also supposed to make its first launch in ’20, and has been delayed for the same reasons.

These delays have cost both companies dearly. For example, had each been operational as planned, they might have won some or all of the launch contracts that OneWeb lost from the Russians. Instead, that business went to SpaceX.

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Blue Origin’s engine division manager leaves company; first BE-4 engines arriving in May

9:48 am

Capitalism in space: The head of Blue Origin’s rocket engine division has decided to leave the company, even as it was revealed that the first flight worthy BE-4 engines will not be delivered to ULA until May at the earliest.

According to company sources, the first two BE-4 flight engines are in final production at Blue Origin’s factory in Kent, Washington. The first of these engines is scheduled to be shipped to a test site in May for “acceptance testing” to ensure its flight readiness. A second should follow in reasonably short order. On this schedule, Blue Origin could conceivably deliver both flight engines to United Launch Alliance in June or July. Sources at Blue Origin and United Launch Alliance say development versions of the BE-4—which are nearly identical to the flight versions—have been performing well in tests.

Upon receiving the engines, United Launch Alliance plans to install two of the BE-4s on the Vulcan rocket for a debut launch as soon as possible. While at the Satellite 2022 conference in the District of Columbia, United Launch Alliance CEO Tory Bruno on Tuesday said he still anticipates that Vulcan’s debut launch will occur in 2022. However, a summertime delivery would be a very tight schedule for United Launch Alliance.

ULA was initially promised these engines more than three years ago. The delay not only put its Vulcan rocket three years behind schedule, it has delayed the development of Blue Origin’s own orbital rocket, New Glenn, by more than three years as well.

To supply the needed engines for both rockets Blue Origin will need to establish a production line that can churn them out at a much faster pace than indicated so far. Whether it can remains an unknown, with the exit now of the head of the company’s engine division making that unknown even more worrisome.

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Blue Origin expands its rocket engine factory in Alabama

9:04 am

Capitalism in space: Blue Origin yesterday revealed that it is hiring 300 more engineers and expanding the rocket engine factory in Alabama in order to produce flight worthy BE-3 and BE-4 engines.

Blue Origin in Huntsville spent the pandemic supporting the company’s main engine plant in Kent Washington with parts for the company’s BE-3 and larger BE-4 engines, [site lead Nathan] Harris said. “We are now actually in the process of building our first set of complete engines through our facility,” he said. Those first engines will be produced this year.

…“We’re getting very close,” Harris said. “They’re still doing quite a bit of retrofitting. As you learn, anytime you retrofit something that’s over 60 years old, it takes a little bit more and there’s a little bit more that you unearth that was undiscovered.”

Harris said he expects to be testing the BE-3 “in the next couple of months followed shortly by the BE-4.” [emphasis mine]

This may be good news for both ULA’s Vulcan rocket as well as Blue Origin’s own New Glenn rocket. Both need the BE-4 engine, and both have been delayed years because it has not been ready on time. While the engine problems appear to have been resolved, Blue Origin had not put any thought into developing a practical and affordable manufacturing process that would allow it to build enough engines to serve both itself and ULA.

This expansion at the engine factory suggests the company is finally moving into its production phase. The highlighted sentence above however also tells us that the first flight worthy BE-4 engines are still months away, which will further delay launch of Vulcan and New Glenn. It is now certain that neither will launch this year, putting both rockets more than three years behind schedule.

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Blue Origin’s CEO wants to build more suborbital New Shepard spacecraft

9:56 am

Capitalism in space: Bob Smith, Blue Origin’s CEO, declared yesterday that the company has more space tourist customers than it can fly on its single New Shepard suborbital spacecraft, and wants to build more to handle the potential traffic.

Jeff Bezos’ space company Blue Origin flew 14 people to space in 2021, and CEO Bob Smith on Thursday said the firm needs to build more of its New Shepard rockets to meet the demand from the space tourism market. “I think the challenge for Blue at this point is that we’re actually supply limited,” Smith said, speaking at the FAA Commercial Space Transportation Conference in Washington.

If true, this is good news, for the suborbital tourist market. It means there might be enough business for both Blue Origin and Virgin Galactic to survive and make money, at least for a few years.

At the same time, Smith’s focus seems wildly misplaced, since it is the orbital market, not the suborbital space tourism market, where the future lies, as well as the really big money. Putting tourists on short ten minute hops to space might be exciting right now, but very soon it will seem very passe, as more and more orbital tourist flights take place.

I wonder if anyone asked Smith about the status of Blue Origin’s orbital rocket, New Glenn, which remains untested and years behind schedule, all because.the BE-4 engine that will power it is also years behind schedule. It would be nice to know when the first flightworthy engines will be delivered to ULA, as well as installed on New Glenn. Those engines were promised more than a year ago, and are still not a reality.

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Blue Origin successfully tests fairing for New Glenn rocket

9:45 am

Capitalism in space: Blue Origin has successfully tested the jettison of the two fairing halves that will be used on its orbital New Glenn rocket.

The test took place at NASA’s Glenn Research Center in Ohio. The company’s video, available at the link, is like all such videos made by all these companies nowadays, filled with dramatic music in order to make it seem like a movie trailer. The jettison itself occurs near the end of the video, and only shows the separation..

This success is encouraging. Moreover, according to Scott Henderson, Blue Origin’s vice president of test and flight operations and Florida site director, they have also completed the launchpad in Florida.

The first launch of New Glenn is presently targeted for late this year, so these successes indicate that launch is getting close. However, everything still hinges on the production of the company’s BE-4 rocket engine, more than two years behind schedule. Until a flightworthy engine is finally available, that first New Glenn launch will remain an ephemeral dream.

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U.S. military adds Blue Origin to its point-to-point space cargo development program

9:50 am

Capitalism in space: The U.S. military on December 17th signed an agreement with Blue Origin to add it to its point-to-point space cargo development program.

The command last year signed similar agreements with SpaceX and with Exploration Architecture Corp. (XArc). Blue Origin is the third company to ink a CRADA [as these development contracts are called] for the rocket cargo program.

Under CRADAs, companies agree to share information about their products and capabilities but the government does not commit to buying anything. U.S. TRANSCOM’s analysis of industry data will inform the newly created “rocket cargo” program led by the Air Force Research Laboratory and the U.S. Space Force. The Air Force in its budget proposal for fiscal year 2022 is seeking $47.9 million to conduct studies and rocket cargo demonstrations. [emphasis mine]

I highlight the total budget of this program to show that this is a very small government program. The cash it provides these three companies is nice, but it is chicken feed when compared with the total cost of development. It certainly will not result in a faster pace at Blue Origin in developing its New Glenn rocket, which is presently two years behind schedule with further delays almost certain because its BE-4 rocket engine is not yet ready for mass production.

Whether the program itself is a good thing, or merely another example of government crony capitalism, is open to question. The practicality of using either Starship or New Glenn for cargo transport remains very unproven, especially for New Glenn, which was not designed with such a purpose in mind and cannot land its upper stage on Earth as Starship can.

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More delays for Blue Origin’s BE-4 rocket engine

9:35 am

Capitalism in space: According to a report yesterday at Ars Technica, more delays are expected in the delivery of Blue Origin’s BE-4 rocket engine to ULA, possibly preventing the first launch of Vulcan from occurring in ’22.

Testing suggests the engine itself is functioning well. However:

Blue Origin is unlikely to deliver two flight-ready versions of the BE-4 rocket engine to United Launch Alliance (ULA) before at least the second quarter of 2022, two sources say. This increases the possibility that the debut flight of ULA’s much-anticipated new rocket, Vulcan, could slip into 2023.

Vulcan’s first stage is powered by two BE-4 engines, which burn methane and are more powerful than the space shuttle’s main engines. The sources said there recently was a “relatively small” production issue with fabrication of the flight engines at Blue Origin’s factory in Kent, Washington. [emphasis mine]

Translation of the highlighted words: We have built the engine, it is working great, but we have suddenly discovered we haven’t figured out the mass production process for building it quickly and in large numbers so as to support numerous launches by both ULA’s Vulcan and Blue Origin’s New Glenn rockets.

ULA claims it can get Vulcan off the ground only a few months after getting those flightworthy BE-4 engines because it has done most of the design work using the dummy “pathfinder” BE-4 engines Blue Origin provided last year. Don’t believe it. The company is going to have to install working engines on Vulcan, and then do static fire tests to validate not only the rocket but its entire launch process. Such testing usually takes months, and is rarely completed in less than half a year, even by SpaceX.

These problems at Blue Origin means that both Vulcan and New Glenn will likely launch more three years behind schedule. Instead of 2020, both will fly no earlier than 2023, at best.

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BE-4 engine delayed until ’22

9:36 am

Capitalism in space: The CEO of ULA, Tory Bruno, admitted yesterday that the first production versions of Blue Origin’s BE-4 rocket engine, required for his company’s new Vulcan rocket, will not be delivered until until early ’22.

Bruno had previously said he expected the engines in late 2021 but on Friday he confirmed the BE-4s will not arrive until early 2022. “I was hoping to get those engines for Christmas. I had giant stockings at home waiting for them,” Bruno quipped in the CNBC interview.

“I’ll say it’s taking them a little longer to fabricate my production engines. They’re in the factory now being built at Blue Origin,” said Bruno. “The COVID epidemic has affected them and their supply chain and it’s just taking a little bit longer, but they’re doing very, very well,” he added. “There’s been no problems with them and in fact, we’re doing the final testing, or what we call certification testing. And that is just going really, really well.”

It appears that Blue Origin is dealing with the difficulties of production, not design, at this point, the same kind of issue that SpaceX recently revealed with its Raptor engine. Blue Origin needs to be able to manufacture these engines at a somewhat high pace, as both ULA’s Vulcan and Blue Origin’s New Glenn rocket use it. It appears that in designing it Blue Origin didn’t think about the manufacturing until very late in the game.

Bruno also said that he plans on flying Vulcan twice in ’22. We shall see.

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Amazon picks rocket startup ABL to launch 1st two prototype Kuiper satellites

3:59 pm

Capitalism in space: Amazon has chosen the smallsat startup rocket company ABL to launch its first two prototype Kuiper satellites, with that launch targeted for ’22.

KuiperSat-1 and KuiperSat-2 will reach orbit via the RS1, a new rocket developed by California-based ABL Space Systems. Amazon also announced today that it has signed a multi-launch deal with ABL to provide these early Project Kuiper launches.

The 88-foot-tall (27 meters) RS1 is capable of launching 2,975 pounds (1,350 kilograms) of payload to LEO, according to its ABL specifications page. ABL is charging $12 million for each launch of the two-stage rocket. The RS1 has not flown yet, but ABL has said that it aims to conduct a debut launch from Alaska’s Pacific Spaceport Complex before the end of 2021.

Earlier this year, Amazon announced that it had signed a deal with United Launch Alliance (ULA), whose Atlas V rocket will loft operational Project Kuiper craft on nine different launches.

Does anyone notice what rocket company has not won these contracts, even though its owner is also Amazon’s founder and biggest shareholder? That’s right, as far as I can tell, Blue Origin’s New Glenn rocket has apparently not won any contracts to launch Amazon’s Kuiper satellites. Notice also that the deal with ULA uses its Atlas-5 rocket, not its new Vulcan rocket, even though ULA wants Vulcan to replace the Atlas-5 beginning in ’22.

Since both New Glenn and Vulcan depend on Blue Origin’s troubled BE-4 rocket engine, these contracts strongly suggest that the engine’s technical problems have not yet been solved, and that neither rocket will be flying in ’22 as both companies have promised.

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Sierra Space teams up with Blue Origin to build its Life space station

10:45 am

Proposed Orbital Reef space station

Capitalism in space: Sierra Space and Blue Origin today announced [pdf] that they are forming a consortium of space companies to build a space station they dub Orbital Reef. From the press release:

The Orbital Reef team of experts brings proven capabilities and new visions to provide key elements and services, including unique experience from building and operating the International Space Station:

  • Blue Origin – Utility systems, large-diameter core modules, and reusable heavy-lift New Glenn launch system.
  • Sierra Space – Large Integrated Flexible Environment (LIFE) module, node module, and runway-landing Dream Chaser spaceplane for crew and cargo transportation, capable of landing on runways worldwide.
  • Boeing – Science module, station operations, maintenance engineering, and Starliner crew spacecraft.
  • Redwire Space – Microgravity research, development, and manufacturing; payload operations and deployable structures.
  • Genesis Engineering Solutions – Single Person Spacecraft for routine operations and tourist excursions.
  • Arizona State University – Leads a global consortium of universities providing research advisory services and public outreach.

I suspect that this deal is actually telling us that Jeff Bezos is spreading some of his Blue Origin money to help finance Sierra Space’s work. The deal also appears to be an effort to generate work for Blue Origin’s not-yet-launched New Glenn rocket and Boeing’s not-yet launched Starliner capsule.

The release says nothing about target dates, but the overview [pdf] on the Orbital Reef website says they are aiming for the second half of this decade.

While the success of such a project can only increase the competition and lower the cost to orbit, thus making the settlement of space more likely, this announcement reeks of the same kind of high-minded promises that came with Blue Origin’s Blue Moon lunar lander: Big plans by the best and most established space companies, with little firm commitment by these companies to actually build anything.

Compared to the Blue Moon lunar lander project, however, this project has one very significant difference that could make it real. Orbital Reef is not being touted in order to win a government contract. It is being touted as a commercial station for private customers. Such a project will require these companies to either invest their own money, or obtain outside investment capital, to build it. To make money they can’t sit and wait for their customers to pay for it, since customers never do that (except the government). They need to first build it.

Meanwhile, the BE-4 engine is not yet flight worthy, so that Blue Origin’s New Glenn rocket remains no closer to launch, even though it is now approaching two years behind schedule.

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ULA to no longer sell Atlas-5 launches

9:36 am

Capitalism in space: In an interview ULA’s CEO Tory Bruno has announced that they have contracts on all of the company’s remaining Atlas-5 rockets, and will no longer be offering that rocket for new sales.

“We’re done. They’re all sold,” CEO Tory Bruno said of ULA’s Atlas V rockets in an interview. ULA, a joint venture between Boeing and Lockheed Martin, has 29 Atlas V missions left before it retires sometime in the mid-2020s and transitions to its upcoming Vulcan rocket, Bruno said. The remaining Atlas V missions include a mix of undisclosed commercial customers and some for the Space Force, NASA, and Amazon’s budding broadband satellite constellation, Project Kuiper.

This means that the company is now firmly committed to its Vulcan rocket, which also means it is entirely committed to the repeatedly delayed BE-4 engine that Blue Origin is building for that rocket. This announcement suggests that Bruno is confident that the BE-4’s problems have been overcome, and that Blue Origin is about to begin regular assembly of the many flightworthy engines ULA will need.

If so, this is really good news. It not only means that Vulcan launches will finally begin, but that Blue Origin might also begin flying its New Glenn rocket. Both will give the U.S. some competitive options for getting big payloads into space. Right now the only real choice at a reasonable price is SpaceX, and having one choice is never a good thing.

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