Orbex has developed one of the most advanced, low carbon, high performance micro-launch vehicles in the world. Photo: courtesy of OrbexAhead of its inaugural rocket launch in 2026, UK-based orbital launch services company
Orbex has accelerated production of its carbon-fibre Payload Avionic Module (PAM) by utilising
MSP’s PerfectPart metrology software. The move has cut part setup time from 5hr to just 30min, making the process 900% faster per part and overcoming longstanding challenges with distortion.
The introduction of these CNC metrology solutions has also halved overall production time, simplified fixturing, and given Orbex confidence that parts will be machined right-first-time. As the company ramps up production, MSP has provided a repeatable and scalable process using Orbex’s existing equipment.
Gavin Belton, a CNC operator at Orbex, said: “The PAM is a large, composite thin-walled part, and the lay-up is delicate in places. The risk of distortion makes it difficult to know exactly where to machine.” Previously, alignment was tricky, took a minimum of 5hr, and distortion often led to windows and pockets being machined incorrectly, causing assembly issues and re-work. Mr Belton added: “The parts are worth tens of thousands of pounds and take around six weeks to produce, so if we lose one it is time, money and material we cannot get back.”
MSP’s PerfectPart suite was introduced to ensure accurate alignments and eliminate errors in probe setup and CNC machine calibration. The process begins with AutoClock and NC-Checker, which remove human error from probe calibration and assess machine geometry. Mr Belton explained: “Immediately an issue was flagged in the C and B axes which could have caused holes on the outside diameter to have been misaligned. The 30min check helped the machine tool vendor work out what the error was likely to be, and make any tweaks before machining began.”
It has made life easierTo tackle alignment challenges, Orbex deployed NC-PartLocator, which measures the part using five-axis probing and automatically generates a best-fit alignment in 6deg of freedom. The updated alignment is uploaded to the controller without program edits, compensating for distortion and removing misalignment errors. Mr Belton continued: “When you press the Go button, you can see the alignment coming through and know you are going to get out exactly what you expect. The speed with which everything is set up, has made life much easier.”
Pictured right: Orbex manufacture the carbon-fibre structures for its launch vehicles using its CMS Ares machineThe results speak for themselves — setup time has been reduced from two days to one, and fixturing simplified. Mr Belton added: “Rather than having to dowel everything down and constrain the part, we have been able to produce a simpler fixture. Furthermore, we do not have to skim the fixture each time — we can use it as it is, and the MSP Best Fit alignment will come in and work out what it should be. It saves us lots of time and effort.”
Mr Belton concluded: “The whole package is a no-brainer really. The risk reduction when machining such a high-value part cannot be understated.” With Orbex’s launch date approaching, MSP PerfectPart will play a key role in scaling production. “We currently only have one CMS machine, so because we have essentially increased its capacity, it will ease any bottlenecks. When we do decide to buy more, the simplicity of the MSP package means we will be able to drag and drop that process onto another machine so we can transition into production easily, keep quality high, and hit the ground running.”
By saving time and protecting every part from costly errors, Orbex is well positioned to deliver on its mission to redefine UK space manufacturing.