How can rocket stages be reused?

Rocket stages are the segments of a rocket that separate and fall back to Earth after propelling the payload to its destination. Reusing them can reduce the cost and environmental impact of space exploration, but how is it done? In this article, you will learn about the challenges and benefits of rocket stage reuse, the different methods and technologies involved, and some examples of successful and future reusable rockets.

1 Challenges of reuse

Reusing rocket stages is not easy. They have to withstand extreme temperatures, pressures, speeds, and vibrations during launch and reentry. They also have to be designed to land safely and precisely, either on a platform or a runway, without damaging themselves or others. And they have to be refurbished and inspected for the next launch, which can take time and money. Therefore, reusing rocket stages requires careful engineering, testing, and quality control.

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RaviTeja Duggineni

Founder & CEO at ResearchSat | Aerospace Engineer | Advancing Therapeutics through Microgravity Research 🚀 💊🧬
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From a materials science perspective, the historical design of rockets has prioritized a high strength-to-weight ratio. This imperative has governed material selection, often leading to single-use designs due to challenges in addressing fatigue loading. The materials used must withstand dynamic loads ranging from high g-forces to vacuum pressures, as well as extreme temperature gradients, from cryogenic conditions to high radiation temperatures. These severe operating conditions often result in a loss of material’s natural elasticity and an increase in brittleness, thus presenting significant challenges to reusability without thorough inspections.

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2 Benefits of reuse

Despite the challenges, reusing rocket stages can offer significant advantages. The main one is reducing the cost of launch, since building new stages for every mission is very expensive. According to SpaceX, one of the pioneers of reusable rockets, reusing the first stage of its Falcon 9 rocket can save up to 70% of the launch cost. Reusing rocket stages can also reduce the amount of debris and pollution in space and on Earth, since fewer stages are discarded or burned up in the atmosphere. Additionally, reusing rocket stages can increase the frequency and reliability of launches, as well as enable new types of missions, such as reusable lunar landers or interplanetary transports.

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3 Methods of reuse

There are different ways to reuse rocket stages, depending on their design and function. The most common method is vertical landing, which involves using thrusters, fins, and legs to slow down and stabilize the stage as it descends and touches down on a landing pad or a ship. This method is used by SpaceX for its Falcon 9 and Falcon Heavy rockets, and by Blue Origin for its New Shepard rocket. Another method is horizontal landing, which involves using wings, parachutes, and landing gear to glide and land the stage on a runway. This method is used by the Space Shuttle for its orbiter and by Sierra Nevada Corporation for its Dream Chaser spacecraft. A third method is partial reuse, which involves recovering and reusing only some parts of the stage, such as the engines or the fairing. This method is used by United Launch Alliance for its Vulcan rocket and by Rocket Lab for its Electron rocket.

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RaviTeja Duggineni

Founder & CEO at ResearchSat | Aerospace Engineer | Advancing Therapeutics through Microgravity Research 🚀 💊🧬
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The Space Shuttle's horizontal landing approach exemplifies an effective reuse method, leveraging its aerodynamic design, wings, and tail to harness wind dynamics during landing. This technique enhances control and stability, reducing reliance on propulsion systems for descent. Additionally, reengineering cryogenic fuel tanks to be more rugged and functional is another vital strategy. By enhancing the durability and performance of these tanks, the overall reliability and reusability of rockets can be significantly improved, contributing to more sustainable and cost-effective space missions.

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4 Technologies of reuse

Reusing rocket stages requires various technologies to make them durable, controllable, and recoverable. For example, reusable engines must be resistant to high temperatures and pressures, and have efficient cooling and ignition systems. Examples of these are the Merlin engines of SpaceX, the BE-3 engines of Blue Origin, and the RS-25 engines of the Space Shuttle. Additionally, reentry systems protect the stage from the heat and drag of reentry, and allow it to maneuver and orient itself. Examples of these are the PICA-X heat shield of SpaceX, the RCC tiles of the Space Shuttle, and the Reaction Control System of Blue Origin. Finally, landing systems enable the stage to slow down and land safely and accurately. Examples of these are the grid fins and landing legs of SpaceX, the drogue and main parachutes of Blue Origin, and the wings and landing gear of the Space Shuttle.

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5 Examples of reuse

Several companies and agencies have successfully reused rocket stages for various purposes. For instance, SpaceX has reused the first stage of its Falcon 9 rocket more than 60 times, and the second stage once. Additionally, it has reused the fairing, the nose cone that covers the payload, more than 20 times. The company also plans to reuse the first stage of its Falcon Heavy rocket and Starship, its next-generation reusable spacecraft. Blue Origin has reused the suborbital New Shepard rocket more than 10 times for tourism and research flights. It intends to reuse the orbital New Glenn rocket and Blue Moon lander as well. NASA reused the Space Shuttle more than 130 times for human and cargo missions to low Earth orbit and the International Space Station. The agency plans to reuse the Orion capsule for deep space exploration, and the Gateway for a reusable lunar outpost.

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6 Future of reuse

Reusing rocket stages is becoming more common and feasible, as more companies and agencies develop and improve their technologies and methods. The future of reuse may include more frequent and affordable launches, more diverse and ambitious missions, and more sustainable and responsible use of space resources. However, reusing rocket stages also poses some challenges and risks, such as safety, regulation, competition, and innovation. Therefore, reusing rocket stages requires not only technical expertise, but also ethical and strategic vision.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Cmdr (Dr.⁹) Reji Kurien Thomas , FRSA, MLE℠

I Empower Sectors as a Global Tech & Business Transformation Quantum Leader| Stephen Hawking Award 2024| Harvard Leader | UK House of Lord's Awardee | Fellow Royal Society | CyberSec | CCISO CISM CCNP-S CEH
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Vertical Landing and Refurbishment - Implement a system where rocket stages land vertically post-mission. This approach, pioneered by companies like SpaceX, allows for inspection, refurbishment, and reuse of rocket stages, significantly reducing costs and waste. Modular Design - Develop rocket stages with a modular design, enabling easy replacement or upgrade of specific components. This strategy enhances the longevity and adaptability of the stages, making them suitable for multiple missions with minimal overhaul. Repurposing for Different Missions - Design stages to be versatile, so they can be repurposed for different types of missions.

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Nasser Al-Baroudi

Attorney at law & Legal consultant @ Egylaw | Leading Commercial Litigator
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This is not my profession...I'm legal counsel. I'm ready to share my knowledge and experience if related laws and legal practices. Thank you very much.

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Alma Thule

Professor, FHEA
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The current volume of space junk only shows that the overall safety measures in space have been sacrificed in the complex trade-off. Collecting the space debris should be the priority. Otherwise, the public support may vanish in the future.

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How can rocket stages be reused?

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1 Challenges of reuse

2 Benefits of reuse

3 Methods of reuse

4 Technologies of reuse

5 Examples of reuse

6 Future of reuse

7 Here’s what else to consider

Aerospace Engineering

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How can rocket stages be reused?

1

2

3

4

5

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7

1 Challenges of reuse

2 Benefits of reuse

3 Methods of reuse

4 Technologies of reuse

5 Examples of reuse

6 Future of reuse

7 Here’s what else to consider

Aerospace Engineering

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