United Launch Alliance (ULA) and Beyond Gravity, a manufacturer of rocket parts, are currently investing $140 million to expand their operations in northern Alabama, according to reports. This development involves the construction of two new facilities in Decatur, Alabama.
The facility in Decatur, Alabama, is responsible for providing carbon fiber composite components to ULA's Atlas rockets, including the payload fairing for the Atlas V-500 launcher and the interstage adapter for the Atlas V-400.
According to the BIS Research report, the space carbon fiber composite market is projected to reach $1.67 billion by 2033 from $0.39 billion in 2022, growing at a CAGR of 14.10% during the forecast period 2023-2033.
Furthermore, an $80 million expansion is planned for Beyond Gravity's production facility, while a new ULA receiving warehouse and finished goods staging facility will be built at the cost of $60 million.
Here’s the Compete Story
According to Darren Drinkwater, who serves as the Director of Production Operations at ULA, “the $140 million investment in Decatur is just one part of a larger $300 million investment in the region.” This investment will cover a range of expenses, including the construction of new buildings, procurement of equipment, and the expansion of the manufacturing capabilities of ULA's existing facility.
The two new buildings will be constructed by Turner Construction and are expected to be finished by the first quarter of 2024, as confirmed by Drinkwater. Following their completion, ULA's Decatur campus will encompass over 2.2 million square feet of space. Currently, ULA's main factory in Decatur covers approximately 1.5 million square feet, with an additional 132,000 square feet leased by Beyond Gravity.
According to Drinkwater, Beyond Gravity (formerly known as RUAG Space) shifted the production of payload fairings and interstage adapters from Zurich and Emmen in Switzerland to its Decatur facility in 2017. The manufacturing process was moved to a factory that was originally constructed for Boeing in 1997.
Similar Ongoing Projects for Space Carbon Fiber Composites
There is a predicted increase in the demand for carbon fiber composite materials in the space industry over the projected years (2023-2033). This growth is expected to be driven by a variety of factors, including the emergence of low Earth orbit satellite constellations, the development of small sat launchers that are reusable, and the undertaking of multiple interplanetary and deep space missions.
In context to recent developments, Beyond Gravity was contracted by Amazon to create and supply the dispenser system for Project Kuiper in March 2022, which is valued at $10 billion and aims to deliver high-speed broadband connections globally. The company was also awarded a contract by ULA for the manufacturing of 38 payload fairings (rocket nose cones) to be used in ULA's Vulcan rockets, providing protection for Amazon's satellites during launch and deployment.
As a result of these contracts, Beyond Gravity increased its production capacity in the U.S. and decided to establish a new manufacturing facility in Decatur. This facility is anticipated to generate 200 jobs and double the company's production capacity and workforce in Decatur. The new facility will span 250,000 square feet, including 30,000 square feet of warehouse space and 20,000 square feet of office space. Beyond Gravity aims to produce 10 fairings annually after the facility becomes operational in early 2024.
Conclusion
According to Nilopal Ojha, Principal Analyst, BIS Research, “Space infrastructure is on the rise and particularly the small satellite constellation is increasing, which is supporting the demand for space carbon fiber composites.”
Satellite manufacturers are currently focused on the development of specialized space missions for communication and Earth observation. However, there is also significant demand for the production of lightweight components for satellites and launch vehicles, which has led to an increased emphasis on the use of space carbon fiber composites.
