Our Moongoose produces Firefly Composite Rockets
We produce Alpha rocket airframes every fourteen days using our large-scale composite manufacturing systems.
Firefly Aerospace, Inc., a leading provider of economical and reliable launch vehicles, spacecraft, and in-space services, has announced a significant expansion of its manufacturing capabilities by adopting our Automated Fiber Placement Mongoose Hybrid systems for large-scale composite production starting next year.
Once fully operational, these AFP systems will enable the production of the all-composite Alpha rocket airframe in as little as fourteen days, significantly increasing manufacturing speed and efficiency.
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
Tom Markusic
CEO, Firefly Aerospace
Firefly will install the first of the two planned Automated Fiber Placement (AFP) systems in May 2021 at its manufacturing and test facility in Briggs, Texas, where the Alpha rocket will be requalified using AFP manufacturing processes enabled by our technology. A second automated assembly line will be installed at Firefly’s Florida Space Coast facility in Cape Canaveral starting in 2022, ultimately enabling production of up to 24 Alpha rockets per year, while the Briggs plant will transition to automated development builds of the larger Beta launch vehicle.
Our AFP technology leverages the same advanced composite manufacturing processes increasingly used by leading aerospace companies to produce next-generation airframes for commercial aircraft and defense platforms, including the Boeing 787, Airbus A350, and F-35. Once fully operational, the system will manufacture all carbon-fiber structures of the Alpha rocket—including barrels, fairings, domes, and payload components—in as little as 14 days.
Firefly’s Mongoose Hybrid system will be the first equipped with our Hawk fiber delivery module, specifically designed and tested to ensure high productivity and reliability when laying up composite materials on mildly curved surfaces. The Mongoose Hybrid platform also features our automatic exchange of multiple composite manufacturing modules operating in adjacent work zones, enabling fully automated layup across multiple tools without human intervention.
These new automated rocket manufacturing facilities will deliver significant advantages, including a 30–50% reduction in composite material waste, improved production repeatability, reduced manual labor, shorter build times, and a tailored, optimized structural design that further reduces both weight and overall production costs.
Our AFP technology leverages the same advanced composite manufacturing processes increasingly used by leading aerospace companies to produce next-generation airframes for commercial aircraft and defense platforms, including the Boeing 787, Airbus A350, and F-35. Once fully operational, the system will manufacture all carbon-fiber structures of the Alpha rocket—including barrels, fairings, domes, and payload components—in as little as 14 days.
Firefly’s Mongoose Hybrid system will be the first equipped with our Hawk fiber delivery module, specifically designed and tested to ensure high productivity and reliability when laying up composite materials on mildly curved surfaces. The Mongoose Hybrid platform also features our automatic exchange of multiple composite manufacturing modules operating in adjacent work zones, enabling fully automated layup across multiple tools without human intervention.
These new automated rocket manufacturing facilities will deliver significant advantages, including a 30–50% reduction in composite material waste, improved production repeatability, reduced manual labor, shorter build times, and a tailored, optimized structural design that further reduces both weight and overall production 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. 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.
Chip Storie
CEO at Ingersoll Machine Tools
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. 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
Tom Markusic
CEO, Firefly Aerospace
Firefly Aerospace is developing a family of launch and in-space vehicles and services designed to deliver industry-leading affordability, reliability, and operational flexibility. Its launch vehicles leverage shared technologies, manufacturing infrastructure, and launch capabilities, enabling LEO launch solutions for payloads of up to four metric tons at one of the lowest costs per kilogram in the small-lift class.
Together with its in-space vehicles—such as the Orbital Transfer Vehicle and the Genesis Lander—Firefly offers the space industry an integrated platform for missions to the Moon and beyond.
The company is headquartered in Cedar Park, Texas, and is financed by Noosphere Ventures, the investment firm of Max Polyakov, based in Menlo Park, California.
Together with its in-space vehicles—such as the Orbital Transfer Vehicle and the Genesis Lander—Firefly offers the space industry an integrated platform for missions to the Moon and beyond.
The company is headquartered in Cedar Park, Texas, and is financed by Noosphere Ventures, the investment firm of Max Polyakov, based in Menlo Park, California.
