October 2025 Company Update

As Terran R development continues to advance, we’re excited to share updates from October across design, build, test, and launch.

Design
This month, the team completed 11 component-level critical design reviews. Significant focus was placed on second stage fluids components, and the team successfully released all machined parts ahead of manufacturing schedules. In avionics, flight designs for the stage controller, high-voltage power distribution box (HVPBD), and actuator controller printed circuit board assemblies (PCBAs) were released.

Build
Flight builds continue across all aspects of Terran R. On the second stage, the team installed the downcomer and forward test adapter on the tank in preparation for acceptance testing. Work on the first stage is progressing with fuel tank friction stir welding complete, barrel painting, completion of dome and barrel mechanical assembly, and installation of composite overwrapped pressure vessels (COPVs). Thrust structure integration also continues, with avionics trays and secondary structure brackets installed. Fabrication of the interstage has begun, with panel production and barrel weldment underway. 

The team successfully completed a weld development campaign on the newly activated horizontal friction stir welder (HFSW). By dedicating this resource to stringer welding, rather than using the vertical friction stir welder, weld capacity and flow time for future flight manufacturing will be improved.

This month, the team completed thrust structure hardware-in-the-loop hardware integration, providing a testbed for vehicle software, avionics, and partner teams to validate designs, automation, and configuration prior to use on the vehicle thrust structure. The milestone brought together a flight-like table build with all thrust structure avionics box designs and quantities, equivalent ground infrastructure, capable test infrastructure that simulates avionics end-point devices, and table functionality to execute flight-like concept of operations (CONOPs). 

In propulsion, two engines were manufactured, assembled, and shipped to NASA Stennis for testing. 

In Long Beach, production capacity continues to expand with the addition of dozens of new powder bed fusion printers and CNC machines, with installations already underway. These additional machines will increase engine manufacturing throughput and support future flight scaling. Propulsion hardware for Terran R’s third flight is already in production, with gimbal sockets, gas generator injectors, and turbopump impellers being printed.

Test
Propulsion testing continues to increase across our test stands at NASA Stennis. On the R stand, the team completed the first round of acceptance testing for a stage one engine and is actively testing the second stage vacuum engine development article. At E2, high-flow thermal shock testing of the stage press valve was executed, simulating the extreme thermal conditions the valve will experience during stage 1 relight.

Preparations for Terran R stage testing continue on the A2 stand, where renovations are underway. Wide-flange steel support beams have been installed to reinforce the structure, and welding on the live ring, the component that holds the stage in place during testing and absorbs thrust and vibration, is in progress. Simultaneously, the environmental control system (ECS) vaporizer, which converts cryogenic liquids into controlled gas flow, has been lifted into position.

Launch
At Cape Canaveral, the team continues to make progress on Launch Complex 16 (LC-16). Work on the horizontal integration facility (HIF) continues, with siding panels and roofing being installed. The water tower is now being erected, currently standing 60 feet (18.3 meters) tall and climbing. Piles for the lightning protection system have been installed, and construction has kicked off on a flare stack for the liquid natural gas (LNG) system. Fabrication of the pad support facility has begun with foundations being poured, and the launch mount rebar is in full swing, with rebar and formwork ongoing throughout the month.

October was a productive month for the program, with significant progress across primary structures manufacturing, acceptance testing, and infrastructure buildout. Each milestone brings us closer to first launch and sets the stage for future missions.