A test of a BE-4 engine at the company’s Launch Site One facility in West Texas on Aug. 2, 2019.
Blue Origin
Jeff Bezos’ aerospace company Blue Origin suffered a rocket engine explosion last month while testing its BE-4 rocket engine, CNBC has learned.
During a June 30 shooting at Blue Origin’s factory in West Texas, a BE-4 engine exploded about 10 seconds into the test, according to several people familiar with the matter. Those people described seeing video of a dramatic explosion that destroyed the engine and severely damaged the test bed infrastructure.
The people spoke to CNBC on condition of anonymity to discuss non-public matters.
The detonated engine was expected to finish testing in July. It was then scheduled to ship to Blue Origin’s customer United Launch Alliance for use in ULA’s second Vulcan rocket launch, those folks said.
A Blue Origin spokesperson confirmed in a statement to CNBC on Tuesday that the company “encountered an issue while testing Vulcan’s Flight Engine 3.”
“No personnel were injured and we are currently investigating the cause,” said Blue Origin, adding that “we already have an immediate cause and are working on corrective action.”
The company noted that it “immediately” notified its ULA of the incident. ULA is the missile manufacturing joint venture of Boeing And Lockheed Martin, which is primarily in competition with Elon Musk’s SpaceX, especially when it comes to the most lucrative military launch contracts. CNBC also asked for comment from ULA on the incident.
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Blue Origin also said it will be able to continue testing engines in West Texas. The company previously built two stands for the tests.
“We will be able to meet our engine supply commitments this year and stay ahead of our customers’ launch needs,” added Blue Origin.
Vulcan delays
The failed test of the BE-4 threatens to further push back the already delayed first Vulcan launch recently moved to the fourth quarter of this year – while Blue Origin investigates the cause of the problem.
Each Vulcan missile uses a pair of BE-4 engines to launch. ULA waited anxiously for years for the first set to be delivered. A month ago, ULA completed a major milestone in preparation for the first Vulcan launch, known as “Cert-1”, with a brief static fire test of the missile using the first pair of BE-4 flight engines.
The Vulcan missile for the Cert-1 mission is on SLC-41 in Cape Canaveral, Florida during testing on May 12, 2023.
United Launch Alliance
As ULA’s mission name “Cert” implies, the company must successfully launch two Vulcans to complete certification of the missile for operational flight by the US Space Force. With ULA retiring its currently operational missiles, Atlas V and Delta IV Heavy, the company needs Vulcan to be certified as soon as possible to fly national security missions.
Last month, Space Force assigned SpaceX and ULA six missions each under the National Security Space Launch Phase 2 program. All six of ULA’s NSSL missions will fly on Vulcan. In addition, ULA is preparing to bid for Phase 3 contracts under NSSL, with the Space Force welcoming increased competition.
Blue Origin’s BE-4 incident comes after ULA spent three months investigating its own test explosion. In March, a separate part of the rocket — known as the upper stage — exploded during a structural test, requiring ULA to partially disassemble the first Vulcan rocket to reinforce the upper stage that had already been installed.
While ULA determined the problem would be fairly easy to fix, it is now testing a change in the thickness of the upper stage steel walls to ensure the fix is sufficient before the company reinstalls an upgraded version.
The new Glenn from Blue Origin
At the same time that Blue Origin needs to get the BE-4 up and running and humming off the production line for its most important customer, the company also needs the engines for its own reusable New Glenn rocket that is under development.
While Vulcan uses two BE-4 engines, each New Glenn missile requires seven BE-4 engines – meaning Blue Origin has to produce dozens per year to power both missiles.
Vulcan and New Glenn both have contracts to fly satellites for another Bezos-founded company, Amazon. Thanks to the successful commercial launch deal, Amazon ordered 38 Vulcan launches and up to 27 New Glenn launches to fly its Project Kuiper Internet satellites over the next few years.
Blue Origin also plans to use New Glenn to fly the lunar lander it is developing under a $3.4 billion NASA contract.
A mass simulator version of a New Glenn missile is being moved for testing in November 2021.
Blue Origin
BE-4, the centerpiece of Blue Origin’s rocket engines, should be ready in 2017, but a host of development issues have meant the company has only recently completed its first flight-ready engines.
Similarly, New Glenn was originally slated for its inaugural flight in 2020. But delays have changed that timeline to unknown, with Blue Origin’s leadership refusing to comment on a new debut launch target for New Glenn in recent public appearances.
Blue Origin opened a large engine production plant in Huntsville, Alabama in 2020 and has done just that expanded its facilities in the area to about 1 million square feet. NASA leased engine test benches at the Marshall Space Flight Center to Blue Origin. The company is testing its smaller BE-7 lunar lander engine there, while it is restoring a larger NASA stand for BE-4 testing at its Texas test facility.