Rocket Lab has postponed the maiden flight of its Neutron launch vehicle to no earlier than 2027. The delay follows manufacturing challenges related to the carbon fibre propellant tank for the first stage.
The company previously tested a full-size tank in January, which failed during hydrostatic pressure testing. CEO Peter Beck attributed this initial failure to the manual hand-layup process performed by a third-party contractor.
Rocket Lab subsequently transitioned to an in-house Automated Fiber Placement machine to improve consistency. However, inspection of the new, thicker forward domes revealed air pockets, or voids, within the composite structure.
These voids occurred because the thicker sections proved difficult to cure properly. The company has identified the cause of these defects and is currently refining the manufacturing process to meet safety standards.
The next steps include building a new forward dome and assembling a complete first-stage tank for further testing. Rocket Lab expects to complete these milestones by the first quarter of 2027.
