Development of the Fairing Structure for CALLISTO

Abstract

In the frame of the project CALLISTO (Cooperative Action Leading to Launcher Innovation in Stage Toss back Operations), DLR, JAXA and CNES develop a demonstrator for a reusable, vertical take-off, vertical landing rocket first stage. The need for reusability of launchers imposes a new set of loads and requirements to almost every part of the rocket. Former flight heritage does not cover the descent and landing phase sufficiently. This lack of information is currently part of many investigations all around the space industry. CALLISTO aims to gather flight data and technological knowledge to achieve such return missions. This paper focuses on the development of the fairing and presents the design, major FE analysis results and performed test activities to achieve a lightweight and reusable space structure. As there is no payload deployed, the fairing is connected to the vehicle for the whole flight acting as a primary structure. Analyses show, that most of the driving loads are induced at the descent phase. In particular the thermal environment during this phase is dimensioning for the CFRP sandwich structure, which is equipped with a cork TPS.