Blue Origin has developed a new rocket engine that delivers more thrust with significantly less hardware. The booster engine, called Northstar, runs on liquid oxygen and liquefied natural gas and produces 715,000 pounds of thrust. It also weighs 30% less than the company’s BE-4 engine, despite higher power.
The new engine is Blue Origin’s second booster propulsion system. Its development also shows how advanced manufacturing techniques can simplify the production of rocket engines. More than 65% of Northstar’s components use additive manufacturing, reducing the number of individual parts and assembly time.
Northstar could bolster Blue Origin’s propulsion portfolio as the company expands its launch capabilities. The announcement also included a major upgrade of its New Glenn rocket, which is getting a new third stage for demanding orbital missions.
Lighter and more powerful engine
Northstar produces 715,000 pounds of thrust, compared to 640,000 pounds for the BE-4. This means a significant increase in performance without an unnecessary increase in mass. According to Blue Origin, the new engine reduces overall mass by 30%.
The engine also contains 50% fewer parts than its predecessor. Additive manufacturing accounts for more than 65% of production. This approach allows engineers to consolidate components that traditionally require separate manufacturing and assembly processes.
Production speed represents another significant improvement. Blue Origin says technicians can assemble Northstar in less than a day. The company has not disclosed its full manufacturing process or the engine’s intended launch vehicle.
Northstar retains several established elements of Blue Origin’s propulsion architecture. It burns liquefied natural gas and liquid oxygen in an oxygen-rich, staged combustion cycle. A single-shaft turbo pump provides fuel delivery.
This combination combines the new engine with the company’s existing drive technology. However, the smaller number of components and lower manufacturing requirements offer a different approach to producing large booster engines.
Blue Origin is accelerating development
Northstar reached development testing just 11 months after receiving program approval. This schedule reflects a development process based on rapid design iterations and internal manufacturing capabilities.
The engine now joins the BE-4 in Blue Origin’s booster engine range. The company also develops engines for upper stage and space applications, providing multiple propulsion options for different mission profiles.
The announcement did not specify Northstar’s first flight date or name a launch vehicle for the engine. These details will help clarify its ultimate role in Blue Origin’s launch operations.
New Glenn reaches the third stage
Blue Origin also unveiled GS3, a new third stage for its New Glenn rocket. The addition expands the vehicle’s ability to reach demanding orbital objectives without relying on additional spacecraft propulsion.
GS3 supports direct insertion into geostationary orbit (GEO) and translunar injection (TLI). Its performance varies depending on the configuration of the New Glenn. The 9×4 vehicle can transport up to 14 tons to GEO and 20 tons to TLI.
The 7×2 configuration supports up to 8 tons according to GEO and 10 tons according to TLI. These capabilities could benefit commercial satellite operators and government customers. GS3 already has a contracted cislunar mission scheduled for 2028.
The stage utilizes Blue Origin’s BE-7 engine, which delivers more than 460 seconds of vacuum-specific pulses on GS3 mission profiles. It also supports multiple firings and longer rollout times for complex orbital maneuvers.
Blue Origin has completed an important structural test for the stage. Engineers pressurized the assembled liquid hydrogen tank to 100% of the maximum expected operating pressure for 2.5 hours. They then reached 150% of that pressure for 10 minutes.
