This article is based on an official press release from the European Space Agency (ESA).

ESA and MT Aerospace Deploy AI to Slash Rocket Inspection Times by 95%

The European Space Agency (ESA) has announced a significant leap forward in the manufacturing of launch vehicles, revealing that the integration of artificial intelligence (AI) into its production lines has drastically reduced quality assurance timelines. In a statement released on January 21, 2026, ESA detailed how its collaboration with German manufacturing partner MT Aerospace has successfully applied machine learning to the production of the Ariane 6 rocket.

The initiative, conducted under ESA’s Future Launchers Preparatory Programme (FLPP), focuses on automating the complex analysis of metal forming and welding. According to the agency, the most immediate impact has been observed in the inspection of friction stir welds, where the introduction of AI has cut analysis time by 95% compared to traditional manual methods.

By shifting from labor-intensive human inspection to data-driven algorithmic monitoring, ESA aims to increase production rates and reduce costs, critical factors in an increasingly competitive global launch market.

Revolutionizing Friction Stir Welding

The core of this manufacturing update centers on Friction Stir Welding (FSW), a solid-state joining technique used to construct the massive fuel tanks for the Ariane 6. Unlike traditional welding, which melts materials to fuse them, FSW uses a rotating pin to generate friction and heat, joining metals without reaching their melting point. While this produces exceptionally strong joints, verifying their integrity has historically required time-consuming analysis.

Under the new system, machine learning algorithms monitor digital telemetry directly from the welding equipment. This includes data points such as weld force, torque, and temperature. The system processes this data to automatically verify the shape and quality of the final weld seam.

Daniel Chipping, ESA Project Manager for Software-Centred and Digitalisation Activities, highlighted the operational impact of this technology:

“Artificial intelligence, such as machine learning, in combination with new digital technologies is transforming launcher manufacturing… from automating complex analysis tasks to reducing tedious machine stop-starts, we are starting to see the benefits across all materials and shaping processes.”

, Daniel Chipping, ESA Project Manager (FLPP)

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Precision in Shot Peen Forming

Beyond welding, the initiative has applied AI to “shot peen forming,” a chaotic process used to shape the dome heads of the Ariane 6 fuel tanks. This technique involves blasting metal sheets with small spherical shots to bend them into specific curves without applying heat, which preserves the material’s structural integrity.

Predicting the Unpredictable

Historically, shot peening has been difficult to model precisely because the impact of thousands of individual shots is physically unpredictable. This often necessitated a trial-and-error approach to achieve the correct geometry. ESA reports that MT Aerospace has now trained machine learning models to predict exactly how the metal will deform under specific bombardment patterns.

This predictive capability allows manufacturers to achieve the desired dome shape with a tolerance of just 2 millimeters, significantly reducing the time required to set up and calibrate the machinery.

Advancing Carbon-Fibre Composites

The FLPP initiative also extends to the “Phoebus” project, a collaboration aimed at replacing heavy metallic upper-stage tanks with lightweight carbon-fibre reinforced plastic (CFRP). Reducing the mass of the upper stage is a priority for ESA, as every kilogram saved on the structure translates to additional payload capacity.

In this application, laser sensors combined with machine learning models are used to detect and classify manufacturing defects “on the fly” during the automated fibre placement process. By identifying issues immediately as layers are applied, the system prevents long production stoppages associated with manual checks, streamlining the fabrication of these complex composite parts.

AirPro News Analysis

The integration of AI into the Ariane 6 supply chain represents a necessary evolution for the European space sector. While new entrants like Relativity Space have garnered headlines for 3D-printing entire rockets, ESA’s approach demonstrates how legacy manufacturers can modernize established industrial processes to achieve similar efficiency gains.

The 95% reduction in weld analysis time is more than a technical statistic; it addresses a primary bottleneck in rocket production. In an era where launch cadence is dictated by how quickly vehicles can roll off the assembly line, removing manual “stop-starts” is essential for Ariane 6 to meet its commercial and institutional targets. By validating these technologies through the FLPP, ESA is effectively de-risking the transition to a more automated, data-centric future for European aerospace.

Sources

Sources: ESA (Primary Source)

This article summarizes reporting by the National Business Aviation Association (NBAA) and official FAA safety alerts.

FAA Issues Urgent Safety Alert on Space Launch Debris Risks Following Starship Incidents

The Federal Aviation Administration (FAA) has issued a formal warning to air carriers and pilots regarding the risks posed by commercial space launch failures. Released on January 8, 2026, Safety Alert for Operators (SAFO) 26001, titled “Airspace Management Considerations for Space Launch Activities,” advises the aviation industry to prepare for “catastrophic failures” that could scatter debris into navigable airspace.

This regulatory move follows a year of record-breaking launch activity and specific high-profile incidents in 2025 involving SpaceX’s Starship program. According to reporting by the National Business Aviation Association (NBAA) and other industry sources, the alert highlights the growing complexity of sharing the skies with experimental rocketry.

The alert comes at a critical time for the National Airspace System (NAS), which has faced strain from a federal government shutdown in late 2025 and early 2026. These staffing challenges previously forced the FAA to restrict commercial launches to nighttime hours to minimize conflicts with passenger traffic.

Understanding SAFO 26001: Debris Response Areas

The core of the new safety alert focuses on the distinction between planned hazard zones and emergency contingency zones. While pilots are accustomed to Aircraft Hazard Areas (AHAs), pre-planned no-fly zones active during every launch, the FAA is now emphasizing the critical nature of Debris Response Areas (DRAs).

A DRA is an airspace volume that is only activated immediately following a launch mishap, such as an explosion or loss of control. The FAA warns that these areas are not theoretical; historical data indicates that debris often falls outside the immediate hazard area during catastrophic failures.

In the text of the alert, the FAA advises:

“Past events have shown that when a mishap does occur, debris has fallen within or near the DRA.”

Federal Aviation Administration, SAFO 26001

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Operational Recommendations for Pilots

To mitigate these risks, the FAA and NBAA are urging operators to adopt conservative flight planning measures when operating near launch corridors, such as the Florida coast, the Gulf of Mexico, and the California coast. Key recommendations include:

• Fuel Reserves: Carrying additional fuel to account for sudden reroutes or holding patterns if a DRA is activated mid-flight.
• Situational Awareness: actively monitoring Notices to Airmen (NOTAMs) for real-time updates on launch status.
• Training: Ensuring flight crews and dispatchers understand the specific geometry and triggers of debris zones.

The Catalyst: 2025 Starship Incidents

The issuance of SAFO 26001 appears to be a direct response to safety data gathered throughout 2025. According to industry reports, a specific incident involving SpaceX Starship Flight 7 on January 16, 2025, served as a primary trigger for heightened scrutiny.

During that test flight, the vehicle experienced a “rapid unscheduled disassembly” over the Caribbean. Debris from the upper stage reportedly fell near areas active with commercial air traffic. Subsequent reporting by The Wall Street Journal in December 2025 revealed that internal FAA documents characterized the event as creating a “potential extreme safety risk.”

Subsequent mishaps involving Starship Flight 8 in March 2025 and Flight 9 in May 2025 further underscored the unpredictability of debris fields generated by massive experimental vehicles. With commercial launches reaching a record 148 in 2024 and projected to exceed 160 in 2025, the statistical probability of airspace conflict has risen significantly.

Industry Reaction and Government Strain

The aviation industry has reacted with caution to the new guidelines. The NBAA has advised its members to take the alert seriously, noting that business jet operators must be prepared for “last-minute” airspace closures that differ from standard planned restrictions.

Dean Snell, NBAA’s senior manager of Air Traffic Services, emphasized the operational difficulty of DRAs compared to standard hazard areas. While AHAs are predictable, DRAs require instant reaction from air traffic control and pilots.

Pilot unions, including the Airline Pilots Association (ALPA), have also expressed concern. Pilots operating over the Gulf of Mexico and the Atlantic are now urged to treat launch windows with a level of caution similar to that used for severe weather systems.

Impact of the Government Shutdown

The timing of the alert coincides with broader systemic issues. A federal government shutdown spanning late 2025 into January 2026 resulted in staffing shortages among air traffic controllers and FAA safety personnel. To manage safety with reduced staff, the FAA issued an emergency order in November 2025 restricting commercial space launches to nighttime hours, typically 10:00 PM to 6:00 AM local time.

AirPro News Analysis

The introduction of Debris Response Areas as a standard consideration for flight planning represents a significant shift in the economics of air travel near spaceports. The requirement for “just-in-case” fuel reserves adds a tangible cost layer for airlines already operating on tight margins. Furthermore, the normalization of “catastrophic failure” planning suggests that regulators no longer view rocket explosions as rare anomalies, but as routine hazards inherent to the rapid iteration cycles of modern commercial spaceflight. We expect this to lead to increasingly rigid flight corridors around the Gulf of Mexico, potentially reducing airspace capacity permanently during launch windows.

Sources:
NBAA: FAA Safety Alert Focuses on Space Launches
FAA Safety Alert for Operators (SAFO 26001)

This article summarizes reporting by the South China Morning Post and official statements from CASC and Galactic Energy. The original SCMP report may be paywalled; this article summarizes publicly available elements and public remarks.

China’s Space Program Hits “Black Saturday” with Rare Double Failure

On Saturday, January 17, 2026, China’s rapidly expanding space sector suffered a significant and rare setback, experiencing two separate launch failures within a span of approximately 12 hours. The incidents, which involved both a veteran state-owned vehicle and a debuting commercial rocket, have been dubbed “Black Saturday” on Chinese social media platforms.

According to reporting by the South China Morning Post (SCMP), these twin failures are viewed by observers as symptoms of the industry’s growing pains as it pushes for an unprecedented launch cadence. The failures halted a long streak of successes for the state sector and marked a stumbling block for one of the country’s leading private space firms.

The Incidents: A Veteran and a Debutant

The two failures occurred at different launch sites and involved vastly different hardware, and risk, currently present in the Chinese aerospace sector.

Failure 1: Long March 3B Stumbles

The first incident occurred at 12:55 AM Beijing Time at the Xichang Satellite Launch Center. The Long March 3B (CZ-3B), operated by the state-owned China Aerospace Science and Technology Corporation (CASC), failed to deliver its payload, the classified Shijian-32 satellite, into orbit.

Official statements from CASC indicate that the rocket performed normally during its first two stages. However, a malfunction in the third-stage booster prevented the satellite from reaching its intended orbit. This failure is particularly notable because the Long March 3B is considered a “workhorse” of China’s orbital fleet. Before this event, the vehicle had maintained a success streak lasting over five years, with its last recorded failure occurring in April 2020.

Failure 2: Ceres-2 Maiden Flight Crash

Less than 12 hours later, at 12:08 PM Beijing Time, the private commercial sector suffered its own loss. The Ceres-2, a new solid-propellant rocket developed by Beijing-based Galactic Energy, failed during its maiden flight from the Jiuquan Satellite Launch Center.

Galactic Energy confirmed via a public statement that the rocket suffered an anomaly shortly after liftoff. The payload included six commercial satellites, notably the Lilac-3, a student-developed microsatellite from the Harbin Institute of Technology. The company issued an apology and stated that an investigation is currently underway. This failure contrasts sharply with the company’s previous success with the smaller Ceres-1 rocket.

Industry Context: The Cost of Speed?

The timing of these failures has sparked discussion regarding the pressure placed on China’s space industry. According to the South China Morning Post, observers suggest these events are part of the sector’s growing pains.

China executed a record-breaking number of launches in 2025, and the 2026 schedule is reportedly even more aggressive, aiming to support major national projects such as the Chang’e 7 lunar mission. Experts cited in reports suggest that the systemic strain of maintaining such a high operational tempo may be impacting quality control processes, even for mature systems like the Long March 3B.

AirPro News Analysis

While launch failures are an inherent risk in spaceflight, the simultaneous failure of a legacy state rocket and a private commercial rocket on the same day is statistically anomalous. At AirPro News, we note that the failure of the Long March 3B is likely the more concerning of the two for Chinese officials. The Ceres-2 failure can be attributed to the inherent risks of a maiden flight and the “fail fast” iteration model adopted by private firms. However, the Long March 3B is a mature system; its failure suggests that supply chain or quality assurance fatigue may be setting in as the state demands higher launch frequencies to meet 2026 goals.

Frequently Asked Questions

What was the “Black Saturday” event?
“Black Saturday” refers to January 17, 2026, when China suffered two rocket launch failures in a single day involving the Long March 3B and the Ceres-2.

What satellites were lost?
The state launch lost the Shijian-32, a classified experimental satellite. The commercial launch lost six satellites, including the Lilac-3, a student-developed research satellite.

Does this affect China’s 2026 space goals?
While investigations are underway, the Long March 3B is a critical vehicle. A lengthy grounding could impact the schedule for other missions, though the Chinese space program has historically shown resilience and the ability to return to flight quickly.

Sources

• South China Morning Post
• CASC Official Statement (via WeChat)
• Galactic Energy Press Release