• Skip to primary navigation
  • Skip to main content
  • Skip to primary sidebar
  • Skip to secondary sidebar
  • NEWS:
  • SatNews
  • SatMagazine
  • MilSatMagazine
  • SmallSat News
  • |     EVENTS:
  • SmallSat Symposium
  • Satellite Innovation
  • MilSat Symposium

SatNews

  • HOME
  • Magazines
  • Events
  • SmallSat Europe Insights
  • Industry Calendar
    • IN PERSON
    • VIRTUAL
  • Subscribe

Firefly Aerospace to Automate Composite Rocket Production with Ingersoll Machine Tools

November 1, 2020

Firefly Aerospace, Inc., announces a major commitment to increase its manufacturing capacity. This will be accomplished by transitioning large parts manufacturing to Automated Fiber Placement (AFP) Mongoose Hybrid systems from Ingersoll Machine Tools beginning next year.

Once fully operational, Firefly’s AFP capabilities will enable it to produce its all-composite Alpha rocket airframe in as little as fourteen days.

“From the outset Firefly chose to utilize 21st century materials and manufacturing processes in our spacecraft and rocket designs. Metallics were the most prevalent aerospace material of the last century; composites, which are stronger and lighter than metallics, are the choice for modern aircraft. Firefly’s Alpha is the world’s largest all-carbon-fiber liquid fueled rocket,” said Firefly CEO Dr. Tom Markusic. “High speed, robotic, large-scale automated fiber placement (AFP) machines, like those produced by Ingersoll Machine Tools, are now widely utilized in the aircraft industry. These machines essentially allow you to 3D print composite structures of very large dimensions (e.g., commercial aircraft), something that is significantly more challenging with metallic 3D printing. Given that we can simply purchase machines which have been developed and proven by the aircraft industry and immediately achieve major cost, weight, and production time savings, it’s obvious to us that AFP is the most efficient and cost-effective approach to future rocket production. Firefly intends to pass those savings on to our customers.”


Firefly will install the first of two planned AFP systems in May 2021 at its manufacturing and test facility in Briggs, Texas, where Alpha will be requalified using AFP manufacturing processes. Firefly’s new Florida Space Coast factory and launch site at Cape Canaveral will house the second automated assembly line beginning 2022 and will ultimately be capable of producing an estimated 24 Alpha rockets per year, with the Briggs plant switching to automated developmental builds of the larger Beta launch vehicle.

Firefly will leverage the same AFP that leading aerospace companies are increasingly using to more efficiently manufacture the latest composite airframes for commercial airliners and government aircraft and fighter jets, ranging from the Boeing 787 and Airbus A350 to F-35s. Once up and running at capacity, Firefly’s AFP system will fabricate all carbon-fiber structures of an Alpha rocket, including barrels, fairings, domes, and payload components, in as little as fourteen days.


Firefly’s Mongoose Hybrid will be the first equipped with Ingersoll’s new Hawk fiber delivery module, designed and tested for high productivity and high-reliability layup of mild curvature surfaces. Mongoose Hybrid also features Ingersoll’s automatic exchange of multiple composite manufacturing modules operating in adjacent workzones, allowing automated layup on multiple tools without human intervention.
Firefly’s new automated rocket factories will produce a broad range of benefits, including a 30-50 percent reduction in composite materials waste, increased repeatability, reduced touch labor and build times, and a tailored and optimized structure that further reduces weight and overall costs.
“Ingersoll is thrilled to bring our vast experience in automated composite manufacturing and robotics across the aerospace industry into the world of space rocketry and exploration with Firefly,” said Chip Storie, CEO of Ingersoll Machine Tools. “Ingersoll has played an important role in enabling breakthrough airframe production for major aircraft designs around the world, including the 787 and A350, and we look forward to supporting Firefly and its innovative approach to the efficient and cost-effective production and further development of its Alpha, Beta, and future spacecraft.”


“As Firefly approaches our first Alpha launch, our focus is transitioning to scaling our operational capabilities to meet the fast-growing commercial, government, and scientific mission demand for space access with the lightest, strongest, fastest built precision-made rocket in the industry,” added Dr. Markusic. “The integration of Ingersoll’s factory automation technology into our production lines in Texas and Florida represents a major investment in our future as a company and in the future of the cis-lunar space economy.”

Filed Under: New Products

Primary Sidebar

Most Read Stories

  • In celebration of Juneteenth
  • Wishing Everyone a Happy July 4th … Independence Day, U.S.A.
  • Eutelsat's efforts to obtain funding to save OneWeb
  • Forrester's Digest: Starlink active in Iran
  • Startical launches the firm's 2nd demo satellite — IOD-2

About Satnews

  • Contacts
  • History

Archives

  • July 2025
  • June 2025
  • May 2025
  • April 2025
  • March 2025
  • February 2025
  • January 2025
  • December 2024
  • November 2024
  • October 2024
  • September 2024
  • August 2024
  • July 2024
  • June 2024
  • May 2024
  • April 2024
  • March 2024
  • February 2024
  • January 2024
  • December 2023
  • November 2023
  • October 2023
  • September 2023
  • August 2023
  • July 2023
  • June 2023
  • May 2023
  • April 2023
  • March 2023
  • February 2023
  • January 2023
  • December 2022
  • November 2022
  • October 2022
  • September 2022
  • August 2022
  • July 2022
  • June 2022
  • May 2022
  • April 2022
  • March 2022
  • February 2022
  • January 2022
  • December 2021
  • November 2021
  • October 2021
  • September 2021
  • August 2021
  • July 2021
  • June 2021
  • May 2021
  • April 2021
  • March 2021
  • February 2021
  • January 2021
  • December 2020
  • November 2020
  • October 2020
  • September 2020
  • August 2020
  • July 2020
  • June 2020
  • May 2020
  • April 2020

Secondary Sidebar

We use cookies to ensure that we give you the best experience on our website. If you continue to use this site we will assume that you are happy with it.
x
Sign up Now (For Free)
Access daily or weekly satellite news updates covering all aspects of the commercial and military satellite industry.
Invalid email address
Notify Me Regarding ( At least one ):
We value your privacy and will not sell or share your email or other information with any other company. You may also unsubscribe at anytime.

Click Here to see our full privacy policy.
Thanks for subscribing!