Scottish project aims to reshape space launches with reusable rockets

A new vision for reusability

Unveiled at the Space-Comm Expo in London, NMIS’s new demonstrator vehicle proposes a radical rethink of second-stage rocket design. Using advanced composite materials and manufacturing techniques inspired by Formula One engineering, the project explores ways to integrate extra functionalities while minimising mass.

Scotland’s emerging role in space launches provides the perfect backdrop for this innovation. The country is already a major hub for satellite production, and with vertical launch sites like SaxaVord Spaceport in Shetland coming online, NMIS sees an opportunity to develop more sustainable and cost-effective launch technologies.

“Satellite assembly is a really important aspect of the Glasgow city region; we make more satellites in Scotland than the rest of the UK,” said Professor Iain Bomphray, Director of the Lightweight Manufacturing Centre (LMC) at NMIS. “But with SaxaVord in Shetland, we have an opportunity to have the vertical launch capability, and we want to support vertical launch.”

The technology behind the concept

The NMIS demonstrator showcased several key innovations:

• Concentric propellant and liquid oxygen tanks: Designed with built-in channels to manage fluid movement and enhance stability.
• Composite heat shield: Lightweight but effective in protecting the vehicle during reentry.
• Integrated systems bay: Houses navigation, control, and recovery systems.
• Digitally enabled manufacturing: Uses advanced techniques like additive manufacturing to enable high-rate production with minimal waste.

Rather than discarding the second stage, NMIS envisions repurposing it for additional missions before it returns to Earth. These could include servicing or recovering satellites, assisting with space debris removal, or conducting further research.

“We felt it was too simple to make a round tube to demonstrate having a bigger first-stage rocket,” said Bomphray. “Nobody really recovers the second stage at the moment. SpaceX are very successful in recovering the first stage, but we thought, ‘Hey, once we've got an asset in space, that's taking a lot of energy to get it there, so it's a valuable asset – let's try to do something useful with it while it's there.’”

Overcoming challenges

Making a second-stage rocket reusable presents significant challenges. Unlike first-stage boosters, which return from lower altitudes, second stages must survive extreme conditions when reentering Earth’s atmosphere. This requires heat shields, aerodynamic stability, and controlled descent mechanisms—all of which add weight.

To counteract this, NMIS is applying its lightweighting expertise to minimise mass while maintaining structural integrity. The vehicle’s aerodynamic profile provides spin stability, allowing for a controlled return. Thermal protection is optimised by ensuring the vehicle enters the atmosphere at the right angle to prevent burning up.

“It's always going to be a trade-off [between] the amount of fuel and the operations that we can do in space, because that's a mass penalty as well,” said Bomphray. The ability to complete extra missions would be an attractive way of improving the economics of a launch.

Positioning Scotland at the forefront of space innovation

Scotland is rapidly becoming a key player in the global space industry. The country’s space sector already contributes over £4bn annually, with nearly 20% of UK space-related jobs based there. By developing reusable second-stage technology, NMIS aims to position Scotland as a leading R&D hub for spaceflight innovation.

“For the Glasgow region, we want to demonstrate that we are a credible R&D partner, that people can come and spend their R&D money,” said Bomphray.

Beyond spaceflight, NMIS hopes the project will stimulate other industries, particularly in advanced materials. Components such as ceramics and silicon carbide fibres, which are currently sourced from outside the UK, could see increased domestic production, strengthening the country’s industrial supply chain.

“We have to be ambitious,” said Bomphray. “We can't let this opportunity go. The space sector is growing exponentially – we want to be part of that.”

Looking ahead

With companies like Skyrora and Orbex already developing multi-stage launch vehicles, the prospect of a reusable second-stage rocket could give Scotland a distinct competitive edge. While still in its early stages, the NMIS concept represents a bold step towards a future where rockets are not just expendable tools, but valuable assets capable of multiple missions.

The project is part of the Stratellite Space and Photonics initiative, which is supported by the Glasgow City Region Innovation Accelerator and Innovate UK.

As Scotland continues to expand its role in the space sector, NMIS’s project demonstrates a crucial lesson: rather than simply reaching for the stars, we should also be thinking about how we return.