Key facts
- Neutron's first flight delayed to 2027 due to manufacturing defect.
- Issue involves voids in carbon composite propellant tank domes.
- Problem discovered during scaling up manufacturing of large booster stage.
- Rocket Lab's Electron rocket has a strong flight record.
Rocket Lab announced Wednesday that its medium-lift Neutron rocket's debut will be pushed to 2027 due to a manufacturing defect discovered in the carbon composite structures of its large booster stage. The issue involves voids, or air pockets, found between layers of carbon fiber in the propellant tank domes, which are among the largest pressurized structures ever made from carbon composite. Engineers identified the voids after a recent design change intended to strengthen the rocket's structure, following a previous propellant tank rupture. Rocket Lab stated that the manufacturing process has been modified and the issue appears to be resolved, with an aft dome passing inspection. The company aims to make orbit on the first try with Neutron, contrasting with its successful Electron rocket, which has completed 97 flights.