Europe's ESA & Avio Team Up for €40M Reusable Rocket Upper Stage
The European Space Agency (ESA) and Italian aerospace giant Avio have signed a €40 million contract to develop a reusable upper stage for future rockets. This marks a significant step in Europe's efforts to reduce launch costs and embrace reusability in space missions.
The reusable upper stage, dubbed a 'mini-Starship', is designed with aerodynamic flaps for controlled reentry, heat shields to withstand temperatures up to 1,600°C, and landing legs for vertical touchdown. It aims to demonstrate its capabilities by returning to Earth and being reflown within 24 months.
The project, part of Europe's ongoing efforts to support an emerging orbital economy, faces challenges like developing robust thermal protection systems, recovery logistics, and rapid refurbishment for economic viability. It supports multiple scenarios, including enhancing Vega's capabilities or integrating with new reusable launchers under ESA's European Launcher Challenge.
The Shanghai Academy of Spaceflight Technology (SAST), a key player in China's space launch capabilities, is involved in the development. Avio's M10 engine, a LOX-methane thruster under development for Vega E, could power the upper stage, offering advantages like denser fuel and easier storage compared to traditional hypergolics or hydrogen.
The reusable upper stage plans draw inspiration from SpaceX's Starship, with Europe focusing on upper stages first, leveraging Vega's small scale for quicker iteration. Reusability promises to halve launch costs, making space more accessible for startups, research, and defense, and bolstering Europe's sovereignty amid reliance on foreign providers. The contract, signed on September 29, 2025, by ESA's Toni Tolker-Nielsen and Avio's Marino Fragnito, signals Europe's commitment to advancing its space capabilities.
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