The ambition of a carbon-neutral spaceport

Orbex is based in Forres, 25 miles from Inverness. The company tests rockets nearby at a former RAF base in Kinloss.

Sustainability has been important to the company from the start. Throughout its development, the protection of the local environment has been a priority. 

In November 2022, Orbex was awarded a contract to operate Sutherland Spaceport on Scotland’s A’ Mhòine peninsula. The company hopes the facility will become the first spaceport in the world to achieve net-zero emissions. A floating road is being installed to protect the surrounding peatlands and ensure it retains its original water balance.  
 
Over the next 30 years, Sutherland Spaceport could contribute an estimated £1 billion to the Highlands and Islands economy. The facility plans to use low-carbon, high-performance micro-launch vehicles to deliver low-cost orbital launch services for small satellites. 

Greener fuels and materials for more sustainable rocket launches

The fuel Orbex uses is made from waste residues and sustainably sourced materials. The bio-propane (BioLPG) produced has a far lower carbon footprint than liquified petroleum gas (LPG) but offers the same performance. 

The use of lightweight materials for rockets is another way to decrease the fuel demands for launches. For this reason, the main structure of the Orbex Prime rocket is built mostly from carbon fibre. Not only is this material robust, but it is also more lightweight than aluminium. 

Scottish rockets made by 3D printing

Through 3D printing, rockets can be manufactured with optimal material use and reduced costs. To take advantage of this technology, Skyrora is developing 3D printing capabilities. It is even possible to capture and reuse metallic dust from processes that would otherwise go to waste. 3D-printed rockets can also lessen the need for transportation to other sites for machining. 

As part of the Made 3D consortium, Innovate UK has awarded Skyrora £500,000 to advance 3D printing capabilities. The company will use these funds to test different metallic alloys for rockets. 

“That allows us to have part of the engine made from Inconel. So, it is strong. But then we can have an inside coating such as copper, which is much lighter with better heat properties,” said Harris.  
 
Post-launch recovery of rockets for reuse is another part of the sustainability plans. Iconel is also used for deep-sea oil pipes. Rockets made from the alloy should withstand the adverse environment before recovery.  

Recoverable and reusable rockets

3D-printed components are also used in the 19-metre-tall vertical launch Orbex Prime rocket. The micro-launcher has a payload of 180kg and features seven engines for its two launch stages. 3D-printed components feature in the propulsion subsystem. 

Designed for reuse, Orbex Prime components have been designed to endure extreme environments in both space and the ocean. 

To shorten supply chains, Orbex also has 3D printing capabilities at its Forres production facility.

Developing space talent

Alongside a history of engineering excellence, universities in Scotland provide the talent and academic expertise to further space research. 

As part of a nationwide scheme in Scotland, Skyrora has hired two graduate apprentices. The combination of education and industry experience equips apprentices with considerable skills for future careers in rocket manufacturing. 

“When they get their full degree, they are probably some of the most experienced rocket techs in the country,” said Harris. “It’s an amazing scheme that we hope we can use more as we continue to grow.” 

Alongside access to talent, Skyrora has partnered with universities to further research in aspects such as engine capabilities.  

Talent in the Scottish space sector

At Orbex, there is an emphasis on working with the local community and businesses. The company has a liaison officer for the local area and takes part in outreach programmes with nearby schools. 

Orbex identifies these programmes and STEM subjects as vital for the next generation of space engineers. They also has a track record of taking interns from the local area.

Orbex has visited Forres Academy and Dallas Primary School while providing Dornoch Academy with classroom resources.

For today’s workforce, there is a focus at Orbex on management skills and expertise in specific areas. The company benefits from access to talent with transferable skills in the oil & gas industry and RAF. 

Orbex has a global reach combined with a commitment to the local area.