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Blue Origin's Rocket Reuse Success Overshadowed by Upper Stage Failure

Ars Technica •
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Blue Origin's New Glenn rocket achieved a milestone Sunday with the first successful reflight of its orbital-class booster, Never Tell Me The Odds, which landed safely after propelling the rocket past Mach 1 and into space. The 321-foot-tall vehicle, powered by seven BE-4 engines, completed a parabolic trajectory before the booster reentered Earth's atmosphere for a smoky touchdown 400 miles downrange. This marked the second flight for the booster, which Blue Origin plans to reuse with engines from its November 2024 mission, aiming to match SpaceX's rapid turnaround times.

The mission's upper stage, however, faltered shortly after separating from the booster. Intended to place AST SpaceMobile's Bluebird 7 satellite into a 285-mile orbit at 49-degree inclination, the upper stage's trajectory error left the payload in a 95-mile orbit, dooming the $100 million asset. AST confirmed the satellite would deorbit within days, though its onboard systems activated successfully. Blue Origin acknowledged the anomaly but provided no immediate technical details, leaving engineers to speculate whether propulsion or guidance systems failed.

This setback contrasts sharply with the rocket's prior success in January 2025, when it precisely deployed NASA's Mars-bound probes. Industry analysts note the failure highlights challenges in scaling reusable upper stages, a critical hurdle for Blue Origin as it competes with SpaceX's Falcon 9, which has reused boosters up to five times in a week. For AST SpaceMobile, the loss delays its bid to challenge Starlink and Amazon's Project Kuiper with a network of 45-60 satellites designed for direct-to-phone connectivity.

The incident underscores risks in Blue Origin's ambitious Artemis program partnerships, where reliability is paramount. While the company celebrates booster reusability progress, the upper stage mishap raises questions about its ability to meet NASA's lunar mission deadlines. AST's insurance recovery and planned 2026 satellite deployments offer a cautiously optimistic path forward, but the episode serves as a stark reminder of the complexities in achieving full rocket reusability.