Stoke Space: Full Rocket Reusability Drives Space App Store Moment - Episode Hero Image

Stoke Space: Full Rocket Reusability Drives Space App Store Moment

Original Title:

TL;DR

  • Full rocket reusability, including the second stage, enables an "iPhone App Store moment" for space, unlocking novel applications by drastically lowering cost and increasing availability.
  • Rapid iteration through in-house manufacturing and testing allows for a one-month development cycle to be compressed to days, fundamentally accelerating technical problem-solving.
  • Custom heat shield technology using liquid hydrogen and a heat exchanger enables the stage two capsule to survive extreme re-entry temperatures, a critical barrier to reusability.
  • Building proprietary software like "Boltline" from day one bridges the gap between garage-level operations and FAA-regulated flight, automating maintenance and operational data.
  • Focusing on a high-performance, fuel-efficient engine for the first stage is a crucial, albeit difficult, technical choice that supports long-life and rapid reusability goals.
  • The ability to make every part in-house reduces iteration cycle dependence on external suppliers, directly tying development timeline and cost to internal iteration speed.

Deep Dive

Stoke Space is pursuing the holy grail of rocket science by developing fully and rapidly reusable rockets, aiming to drastically lower costs and increase access to space. This ambition hinges on solving the critical challenge of re-entry for second-stage capsules, a feat that, if successful, could unlock an "iPhone App Store moment" for space applications by enabling unprecedented availability and novel uses.

The core innovation lies in achieving aircraft-like reusability for the entire rocket system, not just the first stage. While current industry progress has enabled first-stage reuse, significantly boosting launch frequency, second-stage capsules still face destruction due to extreme heat during re-entry at speeds exceeding 17,000 miles per hour. Stoke Space's Andromeda capsule addresses this through a custom heat shield employing a cold liquid hydrogen heat exchanger to absorb re-entry temperatures, supplemented by thrusters for controlled descent. This approach, coupled with a high-performance, fuel-efficient engine for the Nova first stage, is designed for rapid turnaround, allowing for frequent flights without proportional increases in manufacturing and testing infrastructure. This efficiency is crucial for scaling the space economy beyond its current limitations of ~150 commercial launches per year, which are largely dominated by satellite constellation deployments, leaving little availability for new ventures.

The founders, Andy Lapsa and Tom Feldman, leveraged their experience at Blue Origin to identify this unmet need, recognizing that a rigorous, hardware-focused approach to full reusability was necessary. Their decision to leave comfortable jobs to start Stoke Space in 2019 was a significant personal risk, amplified by the onset of the COVID-19 pandemic. Early traction was achieved through intensive engineering and testing, including developing a prototype engine in a backyard shipping container, demonstrating their commitment to tangible hardware progress over theoretical plans. Fundraising proved challenging, particularly with a hardware-intensive business model distinct from the prevailing SaaS focus, and required a strong emphasis on resilience and the ability to "hear no" repeatedly. To date, Stoke Space has raised approximately $90 million, operating with notable efficiency.

The company's strategy emphasizes rapid iteration and vertical integration, enabling them to control their development timeline and costs. By manufacturing most parts in-house, they can quickly integrate lessons learned from testing failures back into new hardware, reducing iteration cycles from months to days. This philosophy extends to their proprietary software, Boltline, which is central to managing operations, tracking vehicle health, and automating maintenance schedules--critical for the rapid turnaround required for full reusability. Stoke Space is building out significant manufacturing facilities capable of producing seven vehicles annually and is establishing a launch site at Cape Canaveral. Their immediate goal is their first orbital launch later this year, with a long-term vision of daily flights.

Success for Stoke Space means transforming space access into a daily, reliable, and cost-effective utility. This shift from a "build and ship" model to a "fly, return, and reuse" paradigm necessitates robust software for managing complex operational data and predictive maintenance. The founders' conviction in the fundamental value of their idea, even amidst significant uncertainty and risk, underscores their belief that full rocket reusability is not just a technical challenge, but a necessary step for the broader advancement of the space economy.

Action Items

  • Build internal operations software: Automate data logging for factory workers to track part service life and maintenance needs, enabling predictive maintenance.
  • Design iterative testing process: Develop a system to rapidly iterate on rocket engine failures, aiming for a 1-2 day cycle from test to re-integration.
  • Create a hardware-in-the-loop testing framework: Integrate avionics, flight computers, and GNC software to simulate 5-10 orbital missions weekly.
  • Audit manufacturing capabilities: Assess the ability to produce all rocket parts in-house to ensure rapid iteration cycles for development.

Key Quotes

"We're building fully, rapidly reusable rockets designed to go to space, through space, and back from space, really to lower costs, improve availability, and improve reliability of access to space."

Andy Lapsa explains that Stoke Space's core mission is to create rockets that can be reused quickly and easily. This focus on rapid reusability is intended to make space access more affordable, more frequent, and more dependable.


"But the second stage is still thrown away on every single mission. That's in large part because the stage two capsule is traveling at 17,000 miles per hour as it drops out of orbit. Because of that high speed, it eventually breaks down as it heats up to more than 2,700 degrees Fahrenheit during its descent."

Tom Feldman highlights a significant challenge in current rocket technology: the upper stage, or second stage, is typically discarded after each mission. He explains that the extreme heat and speed during re-entry make it difficult for these components to survive, leading to their loss.


"What rapid reusability allows you to do is to scale the flight frequency without having to scale your factories and your test facilities and all of the infrastructure that comes with it."

Andy Lapsa points out a key advantage of rapid reusability. He argues that it enables a company to increase the number of launches without a proportional increase in the physical infrastructure needed for manufacturing and testing.


"And then it kind of clicked one day that there is this problem. People are still throwing away rockets, and we really didn't see anybody actively working super hard to attack that problem with rigor, combined with the fact that we thought we had a pretty good idea on how to solve it."

Tom Feldman describes the moment he and Andy Lapsa identified their company's mission. He explains that they recognized the persistent problem of discarding rockets and felt they had a viable solution that others were not aggressively pursuing.


"It felt wildly irresponsible, to be honest. Easily the hardest decision that I've ever made personally. I had a three-month-old at home, and I had a really good paying job that I was quitting."

Andy Lapsa reflects on the significant personal risk involved in starting Stoke Space. He conveys that leaving a secure, well-paying job to found the company, especially with a young child, was an exceptionally difficult decision.


"So the speed at which you can iterate becomes fundamentally important to your ability to do the hard thing as quick as possible. You do have to plan for failure. So when, for example, if you're developing a rocket engine and the engine fails, how soon can you learn the lesson from that one, make any change that you need to change, and get the next one out there?"

Tom Feldman emphasizes the critical role of iteration speed in overcoming complex engineering challenges. He explains that the ability to quickly learn from failures, implement changes, and deploy the next iteration is essential for rapid progress in developing difficult technologies like rocket engines.

Resources

External Resources

Books

  • "The iPhone App Store Moment" - Mentioned as an analogy for the potential impact of fully reusable rockets.

People

  • Andy - Co-founder of Stoke Space, former Jet Propulsion Engineer at Blue Origin.
  • Tom - Co-founder of Stoke Space, former Jet Propulsion Engineer at Blue Origin.
  • John Glenn - Mentioned as the first American to orbit Earth from Historic Complex 14.

Organizations & Institutions

  • Stoke Space - Company building fully and rapidly reusable rockets.
  • Blue Origin - Former employer of Stoke Space co-founders.
  • Y Combinator (YC) - Accelerator program that assisted Stoke Space with fundraising and learning the venture process.
  • FAA (Federal Aviation Administration) - Regulatory body overseeing space launches.

Websites & Online Resources

  • Historic Complex 14 (Cape Canaveral, Florida) - Launch site used by Stoke Space, previously used by John Glenn.

Other Resources

  • Nova - Stoke Space's two-stage orbital rocket.
  • Andromeda - Stoke Space's second stage or upper stage capsule.
  • Bolt Line - Stoke Space's internally developed operational software tool.

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