Relativity Space Takes Flight: Terran 1 Launches as Largest 3D-Printed Rocket in Aerospace History.

In a groundbreaking moment for additive manufacturing in aerospace, Terran 1, the largest 3D-printed object to launch, soared into the skies from the Cape Canaveral Space Force Station in Florida on March 22, 2023. The 33-meter (110-foot) tall rocket and its nine engines were meticulously crafted using 3D printing technology by the innovative aerospace startup Relativity Space at its Long Beach, California factory.

3D Printed Terran 1 Lifting Off Photo Credit: Relativity Space

Named "GLHF" (Good Luck, Have Fun), this historic launch from Launch Complex 16 (LC-16) marked the company's third attempt, albeit without a customer payload. While the mission encountered an unfortunate setback, failing to achieve orbit due to an upper-stage malfunction, Relativity Space remains optimistic, emphasizing that the launch successfully showcased the prowess of their 3D-printed rocket technologies. Notably, the rocket persevered through Max-Q, the highest stress state during a launch, validating the effectiveness of Relativity's novel additive manufacturing approach.

Despite the setback, the company expressed confidence in the achievement, stating on X (FormerlyTwitter),

"This is the biggest proof point for our novel additive manufacturing approach. Today is a huge win, with many historic firsts. We will assess flight data and provide public updates over the coming days."

Relativity Space, the first venture-backed space company to attempt orbit on its maiden flight, broke new ground with Terran 1, which became the first rocket to reach orbit fueled by methalox – a combination of natural gas (methane) and liquid oxygen. Looking ahead, the Terran Rockets are poised to carry payloads of up to 1,250 kg (2,756 lbs) to an altitude of 500 km (310 mi) or Low Earth Orbit (LEO). 

The Design Capabilities of Relativity 3D Printed Rocket. Photo Credit Relativity Space

Further solidifying its presence in the aerospace industry, Relativity Space secured a multi-year, multi-launch agreement with OneWeb, a global space-based communications company. In 2025, Relativity plans to launch OneWeb's low Earth orbit satellites on Terran R, a 3D-printed reusable launch vehicle 20 times larger than Terran 1. This strategic move has positioned Relativity with five signed customers for Terran R, including multiple launches with a backlog exceeding $1.2 billion.

Terran R, designed as a medium-heavy lift, fully reusable launch vehicle, is geared towards meeting the escalating demand for satellite constellation launches and eventual multi-planetary transport. Relativity Space envisions providing both government and commercial customers with affordable access to space through the capabilities of Terran R, marking a significant leap forward in the realm of aerospace manufacturing.

Relativity is rewriting the rules using 3D printing, autonomous robotics, and machine learning in a seismic shift for aerospace manufacturing. This transformative approach has accelerated production and significantly lowered costs, disrupting traditional practices that have been in place for decades.

Relativity's streamlined supply chain, driven by 3D printing, autonomous robotics, and machine learning, allows the company to craft rockets efficiently. In a game-changing feat, the company prints its rockets using 100 times fewer parts in less than 60 days, starkly contrasting industry standards of 18 months or more. Key to this efficiency is the ability to 3D print components as a single piece, layer by layer, incorporating intricate internal channels and complex geometries. SpaceX, Aerojet Rocketdyne, Launcher, Ursa Major, and Orbex are notable players leveraging 3D printing in their rocket manufacturing processes to lower the production cost while producing more rockets.

What sets Relativity apart, however, is its distinction as the first aerospace company to 3D print the entire fuselage of a rocket. Over the six years since its inception, Relativity has pioneered new manufacturing technology centered around its cutting-edge 3D printer, Stargate. The recently unveiled fourth generation of Stargate has elevated print speeds by ten times, positioning Relativity to take production to unprecedented scale and quality levels.

Operating from its expansive one million+ square-foot factory headquarters, Relativity envisions a future where these advanced Stargate printers propel the company to new heights. In-process monitoring allows these printers to analyze prints in real time, swiftly identifying and addressing potential quality issues. Leveraging predictive capabilities, Stargate ensures that fuselages adhere to aerospace dimensional tolerances with precision.

In a testament to its growth, Relativity has tripled its workforce since 2020, employing over 800 individuals across its various locations in Long Beach, Vandenberg, Seattle, Washington D.C., Stennis, and Cape Canaveral. The company is relocating to its new headquarters, which is designed to accommodate over 2,000 employees. This state-of-the-art facility boasts a metallurgical laboratory, powder bed fusion printers, a mission control center, and numerous proprietary Stargate 3D printers.

Relativity Space Headquarters Design in Long Beach, California

Relativity Headquarters Concept Design for Long Beach Cal.

Relativity's Terran R, a medium-heavy lift, fully reusable launch vehicle, is poised to address the surging demand for satellite constellation launches and eventual multi-planetary transport. With a commitment to providing government and commercial customers affordable access to space, Relativity continues to shape the future of aerospace manufacturing through its groundbreaking use of 3D printing technology.

Keywords: 3d printed Rocket Aerospace Terran 1 Relativity