Rocket Lab announced the successful qualification of its groundbreaking “Hungry Hippo” fairing for the Neutron launch vehicle. The innovative structure is now en route to Virginia for the medium-lift rocket’s inaugural launch, clearing a critical development milestone.
Unlike traditional fairings that are jettisoned mid-flight and lost or recovered separately, Neutron’s “Hungry Hippo” design is a core component of its reusability. The fairing halves remain attached to the first stage throughout the entire mission. They open in space to release the second stage and payload before closing again, forming an aerodynamic shield for the vehicle’s return to Earth. This all-in-one approach is a first for the commercial launch industry and is designed to enable rapid vehicle turnaround by eliminating complex offshore recovery operations for fairings.
“We’re building and qualifying Neutron at a pace that will bring needed innovation and competition to the industry,” said Shaun D’Mello, Vice President of the Neutron program. “Shipping this qualified fairing is a fantastic marker of progress.”
To ensure the design can withstand the rigors of launch and re-entry, Rocket Lab conducted an intensive test campaign. Engineers subjected a full-scale fairing to 275,000 pounds of force, simulating the extreme aerodynamic pressure of “Max Q.” The opening and closing mechanism was validated in under 1.5 seconds. Additional tests applied combined torque and bending loads exceeding 125% of expected flight conditions at the canard hubs, where aerodynamic control surfaces are integrated. The program also verified the system’s performance using actual flight avionics, software, and hardware.
With a payload capacity of 13,000 kg to low Earth orbit, Neutron is poised to be the world’s largest carbon composite launch vehicle. The fairing’s qualification keeps the program on schedule for its first launch in 2026. Once in Virginia, the “Hungry Hippo” will be integrated with Neutron’s first stage at Launch Complex 3 for final pre-launch testing, including static fire trials.
