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Building up – not out – the next moon rocket core stage

New platforms enable rocket components to stack vertically earlier in the process, increasing factory capacity.

September 27, 2024 in Space Launch System, Space

Just weeks after delivering Core Stage 2 to NASA, Boeing teams continue progress on setting the foundation for future missions.

Their next task? For Boeing’s team inside the Vehicle Assembly Building (VAB) at Kennedy Space Center in Florida, it’s to complete the installation of vertical integration platforms for high bay 2 (HB2). This bay is a ‘cell’ within the VAB where rockets will be vertically integrated and stored. 

Why it matters: These changes – derived from the experience obtained during development of the first two stages and their production system – will result in significant cost and schedule improvements while allowing improved vehicle access for concurrent assembly, integration and testing.

Vehicle Assembly Building (VAB) To date, the engine integration platform, core stage support platform, the first 3 levels of the core stage access platform, and the east access stairs have been installed. Boeing supplier Futuramic is expected to complete the project in Fall 2024. (Boeing photo)

The Artemis campaign currently uses high bay 3 for final integration of the rockets. The addition of the HB2 platforms enables 360-degree access to the core stage for vertical integration, testing and processing, which reduces cycle and processing time. 

  • This configuration will also allow the teams there to build one core stage a year.
  • Prior to this tooling, Core Stage 1 and 2 were both integrated horizontally at NASA’s Michoud Assembly Facility (MAF) in New Orleans, Louisiana.

With this new capability, while one stage is stacked, awaiting launch, another can be built or stored in the high bay. This change doubles the footprint within the VAB, while also freeing up space at MAF to continue work on the individual elements for Core Stages 3, 4 and 5 and the Exploration Upper Stage.

“This is a large vehicle, and even when it’s not fully integrated, each individual part is massive,” says Dave Dutcher, vice president and program manager for Space Launch System.

Boeing supplier Futuramic is constructing the platform and is expected to complete the project in Fall 2024.

CS3 Engine section In December 2022, Boeing transported the CS3 Engine Section from NASA’s Michoud Assembly Facility (MAF) to Kennedy Space Center (KSC) for processing. (Boeing/Liz Morrell photo)

Go deeper: This new tooling will be used beginning with Core Stage 3 (CS3) integration.

  • In December 2022, Boeing transported the CS3 Engine Section from NASA’s Michoud Assembly Facility (MAF) to Kennedy Space Center (KSC) for processing, as a part of a production and assembly move to KSC for CS3 and beyond.
  • Remaining elements of CS3 are expected to be delivered to KSC in 2025.