Blue Origin has been busy as they continue to work on the New Glenn launch system. While for the most part, public updates and images of progress are rare from Blue Origin, we got a significant sneak peek yesterday of a first stage. Not just any first stage, but flight hardware nearly complete and practically ready for testing.
This is quite a big deal as it confirms some of the work going on behind the scenes and showcases physical hardware. With continued talk of a launch in late 2024, Blue Origin needs to work at a very fast pace and get this hardware on the test stand. Here I will go more in-depth into the new image, why its so significant, what the next few months should look like, and more.
First Stage Flight Hardware
Yesterday, in an image captured by NASASpaceFlight, nearly a full New Glenn first-stage tank could be seen. What’s so significant is the fact that this tank is not a mock-up or structural test article like we’ve seen in the past. Instead, this looks to be a flight capable first stage section that is meant for testing. As far as why this tank is believed to be flight hardware, there are a few reasons. For one, Blue Origin had commented that they would be rolling out flight hardware by December for wet dress rehearsal. Based on the work still left on this specific tank, that aligns with the December timeframe.
Focusing more on the image, this tank section makes up the New Glenn first stage mid-module. In other words, its missing the first stage forward and aft module. Looking at various New Glenn renders puts this in perspective with the help of the livery. For example, you can see on the real image the blue band that wraps around the bottom of this tank. Then on renders this same band can be seen right above the aft module where all the engines are housed. In addition, all along the side near the bottom are what looks like mounting points for the eventual installation of two strakes. These strakes stretch from the bottom of the mid module and connect to part of the aft module.
Finally, at the top, it cuts off right before the final section where the four fins will be located. Once all three of these modules come together, it will be a complete booster. Based on the progress of this mid-section, it’s safe to assume that the other two modules that make up the first stage, are also nearly complete if not ready. In the background of images over the past few months, we have seen hints of these sections including landing legs, aft modules, etc.
You can even see the plumbing at the very bottom which will eventually provide 7 BE-4 engines with propellant. With the increase in production of these engines, there likely are plenty of BE-4 engines ready for installation and eventual testing on New Glenn.
Another aspect that this image highlights is the impressive size of New Glenn. While it’s not as big as the 9m width Starship, it’s still a massive rocket with a 7m diameter. This is much larger than almost all other operational rockets within the industry. Its size relative to nearby cars and structures helps put this in perspective. This specific section is also only about half of the total height when you include the other first-stage modules and the upper stage as well.
All things considered, It’s clear that Blue Origin is very close to testing this first stage. When that does eventually happen, that will be one of if not the biggest milestone in the project’s history. If they are able to attach the other modules in a reasonable amount of time, we can expect a big update from Blue Origin in the coming months regarding this exact hardware. Something to look forward to in the near future.
New Glenn Overview
With this hardware in mind, we can take a closer look at the New Glenn architecture and plan for this vehicle. The New Glenn primary booster is a reusable first stage with a length of 57.5 m (188.5 ft) and a tank diameter of 7 m (23 ft). As partially mentioned before, the stage consists of three sections: aft, mid, and forward. The aft module of the booster contains seven BE-4 LOX/LNG engines in addition to deployable landing legs. The restartable BE-4 engines are intended to provide precision thrust vector control and continuous deep throttle capability to support propulsive deceleration and landing maneuvers, while featuring long design life. The 8.5 m (28 ft) diameter engine skirt protects the engines from atmospheric reentry conditions and contains six stowed landing gear.
The mid module of the booster houses the fuel (LNG) and oxidizer (LOX) tanks. The tanks are made of orthogrid aluminum and are designed to withstand the high g-loads realized during reentry. Large aerodynamic strakes on the aft end of the tanks give the returning first stage enhanced cross-range during descent and reentry. The forward module of the booster features four actuated aerodynamic control fins for attitude control during descent. This section of the booster also provides ground umbilical connections for New Glenn and interstage housing of the two second stage vacuum-optimized BE-3U engines. The forward module houses various guidance navigation & control avionics, including an autonomous flight safety system. The pneumatic pusher stage separation system, which provides positive separation before second stage ignition, is located in the forward module.
Moving up the rocket, the second stage is an expendable LOX/LH2 stage with dual gimballing BE-3U engines with 1,060 kN (240,000 lbf) total thrust in vacuum. The stage also has a tank diameter of 7 m (23 ft) and uses common tooling with the first stage to reduce recurring cost. The length of the second stage tank is 16.1 m (52.9 ft) and the overall length including the two high expansion ratio nozzle BE-3Us is 23.4 m (76.9 ft). Similar to the first stage, the second stage has aft, mid, and forward sections. The aft section consists primarily of the two BE-3U engines, associated load bearing cross-bar thrust structure, and tankage/equipment for long duration operations.
The reaction control system (RCS)/settling system uses tri-axial thrusters distributed in four places along the thrust structure. The second stage aft section integrates with the first stage forward section and provides one of two second stage umbilical interfaces. The mid-section contains all propellant tankage including a forward LH2 tank and an aft LOX tank, separated by a common insulated bulkhead. The tank barrels are orthogrid aluminum construction, and the domes are constructed from welded aluminum. A single external insulated LH2 supply line passes around the LOX tank.
On an actual mission, after second stage separation, the first stage booster reorients itself to reenter the atmosphere aft end first. Through a combination of aerodynamics and propulsive maneuvers, the stage performs a precision landing on the ocean-going platform in the Atlantic Ocean. This process is dependent on a host of factors especially including the BE-4 engine.
Blue Origin highlights that BE-4 was designed from the beginning to be a medium-performing version of a high-performance architecture. A conscious design choice made to lower development risk while meeting performance, schedule and reusability requirements. They point out that they chose LNG because it’s highly efficient, low cost and widely available. Unlike kerosene, LNG can be used to self-pressurize its tank. Known as autogenous repressurization, this eliminates the need for costly and complex systems that draw on Earth’s scarce helium reserves. LNG also possesses clean combustion characteristics even at low throttle, simplifying engine reuse compared to kerosene fuels.
As far as a first launch date, we got some more news just a few days ago. Specifically, early this year in February, NASA awarded Blue Origin and the New Glenn vehicle a mission to Mars carrying two spacecraft. At the time they mentioned that the launch would be sometime in 2024. NASA acknowledged this mission as low priority and high risk. They also pointed out that this type of mission could have significant alternative or reflight opportunities. Either way, the mission is still scheduled and based on the physical progress that NASA has seen.
Very recently, at a November 20 meeting of the NASA Advisory Council’s human exploration and operations committee, Bradley Smith, director of NASA’s Launch Services Program, said the agency’s Mars-bound ESCAPADE smallsats will fly on an “incredibly ambitious first launch for (Blue Origin’s) New Glenn” rocket “around this time next year.” He continued by saying, “We will very likely be the very first launch of New Glenn.”
These comments combined with new images of first-stage hardware are both good signs for Blue Origin. While a launch late next year is still very ambitious, it’s not completely out of the picture. It will all depend on a few different factors including Vulcan’s first flight and the time it takes Blue Origin to assemble and begin testing the first stage. If this process goes smoothly and the testing provides promising results, the company will move even faster toward an actual flight attempt. In addition, Vulcan is set to lift off on December 24th which will be the first flight of the BE-4 engine.
Conclusion
A first stage of New Glenn was just spotted moving between facilities. It’s likely that this hardware could be for flight purposes and will be tested in the coming months. If so, a launch late next year in 2024 seems a lot more possible and within reach. We will have to wait and see how it progresses and the impact it has on the space industry.