United Launch Alliance's Vulcan rocket experienced another booster malfunction during its latest launch from Florida's Space Coast. Moments after liftoff at 4:22 am EST Thursday, a shower of sparks emerged in the exhaust plume, followed by a twisting motion before the rocket recovered and continued to orbit with US military satellites.

This incident bears striking similarities to a booster nozzle failure that occurred 16 months ago on the Vulcan's second test flight. Northrop Grumman builds the Graphite Epoxy Motors (GEMs) used on the rocket, which are larger versions of boosters previously used on ULA's Atlas V rocket. The 72-foot-long solid-fueled motors burn through more than 105,000 pounds of propellant in less than 90 seconds.

ULA officials confirmed an investigation is underway, though details remain unclear. The company, a 50-50 joint venture between Boeing and Lockheed Martin, has faced similar issues before. In the 2024 incident, investigators traced the problem to a manufacturing defect in a carbon composite insulator inside the nozzle. The Vulcan's BE-4 main engines, supplied by Blue Origin, compensated for the thrust differential in both incidents, allowing the rocket to reach its planned orbit despite the malfunctions.