Low-Cost Launch Systems for the Dual-Launch Concept

Abstract : Current launch costs into low Earth orbit (LEO) are extremely high. This study identified cost reductions possible using a dual launch strategy using high-reliability/high-cost launch vehicles for high-value payloads, and lower cost launch vehicles for low-value payloads. The approach was to assess existing expendable launch vehicles for development, production, and operations cost using a parametric mass- based cost model, TRANSCOST 6.2. Performing fewer engine tests, designing structures with lower structural margins, parallel processing, eliminating payload clean room requirements and extensive testing before launch, horizontal integration, lower cost labor, and reduced insurance costs were examined to lower costs. Nearly an order of magnitude reduction can be achieved from current launch costs to LEO for low-value payloads. The use of conventional expendable rocket vehicles, however, keeps costs above S2,000 per kilogram to LEO. Revolutionary methods, such as first stage lasers, eleeflomagnetic and ram accelerators, and upper stage orbiting tethers, were examined to achieve even lower launch costs. The best combination examined uses the ram accelerator and orbiting tether, with an estimated cost of $250-$350 per kilogram into LEO. That might be further optimized to achieve $100/kg. No launch techniques were discovered that show launch costs below $100 per kilogram.