Rocket Lab Delays Neutron Rocket Launch to 2027 Following Manufacturing Issues With Carbon Composites

Rocket Lab announced Wednesday that its medium-lift Neutron rocket will not fly until 2027 due to a manufacturing issue with the vehicle's carbon composite structures. The delay pushes back a timeline that previously targeted a late-2024 debut when the rocket was first introduced in 2021. CEO Peter Beck stated that engineers discovered air pockets, or voids, between layers of carbon fiber inside the propellant tank domes of the reusable first stage.

The flaws appeared after the company increased section thickness and removed joints to strengthen the design following a hydrostatic pressure test failure in January. Because Neutron’s first stage measures 23 feet across, it requires new out-of-autoclave manufacturing processes instead of traditional high-pressure thermal curing chambers. Rocket Lab reported that an aft propellant dome built with an updated procedure has successfully passed inspection.

Beck stated that the fix gives the company confidence to build a new forward dome, though the investigation and rework have delayed the launch to next year. The company still needs to complete final first-stage qualification and testing for the nine methane-fueled Archimedes engines that will power the booster.