Rocket Lab ruptures a Neutron tank during testing

"Rocket Lab suffered a setback after a Neutron Stage 1 tank ruptured overnight while the company was performing a hydrostatic pressure trial at its Space Structures Complex in Middle River, Maryland. Destructive testing is not uncommon, but this test was conducted only to design limits, according to Rocket Lab's statement. "We intentionally test structures to their limits to validate structural integrity and safety margins to ensure the robust requirements for a successful launch can be comfortably met.""

"Neutron is heftier and more complex than the Electron, capable of sending 13,000 kg to low Earth orbit (less than Falcon 9's payload capacity). The rocket is a two-stage launcher designed to be partially reusable. The second stage is enclosed within a hinged fairing, dubbed the "hungry hippo," and is released when the fairing opens. The fairing will then close and the rocket returns to Earth for reuse."

"Before this incident, 2026 was set to be a big year for the Neutron, with a maiden launch planned. It is not clear whether, or to what extent, the tank rupture will cause a delay. "The team is reviewing the Stage 1 test data, which will determine the extent of the impact to Neutron's launch schedule," Rocket Lab said. The tank is constructed from a carbon composite material, as is the vast majority of the Neutron rocket. The question, other than any potential impact on schedule, is whether a handling problem, design defect, or manufacturing is"

During a hydrostatic pressure trial at Rocket Lab's Space Structures Complex in Middle River, Maryland, a Neutron Stage 1 carbon-composite tank ruptured overnight. The test was performed to design limits to validate structural integrity and safety margins. There were no reported injuries and no significant damage to test structures or facilities, but the tank was destroyed. Another Stage 1 tank is in production. The team is reviewing test data to determine the impact on Neutron's launch schedule and will update during the Q4 2025 earnings call. Neutron is a heavier, partially reusable two-stage rocket with a hinged fairing dubbed the "hungry hippo." Questions remain about handling, design, or manufacturing causes.

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