Bengaluru Startup Is Building The World’s First Fully Reusable Medium-Lift Rockets, Cuts Launch Costs – Aims to Achieve What SpaceX Hasn’t

Why do you think space launches are so expensive?

Yes, they involve deep technology and innovation. Large teams consistently work on them, from start to finish.

But space launches are expensive mostly because rockets are not reusable. They burn up in the atmosphere or fall into the ocean after each use.

The result? Each launch becomes as expensive as building a brand-new rocket.

“We are fundamentally changing the game with the reusability of both the upper and booster stages - a world first. The Razor Crest Mk-1 is a first-principles rebuild of how medium-lift launchers should work,” Manu J Nair, co-founder of EtherealX, tells Startup Pedia in an exclusive interview.

Founded in 2022, EtherealX is a Bengaluru-based space startup that is developing private rockets that are fully reusable. This brings down costs and makes launches more efficient than ever.

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HOW IT ALL BEGAN

Hailing from Kerala and growing up in various parts of the country, Manu J Nair has a background in mechanical engineering from the BML Munjal University in Gurugram. He grew up listening to the Vedas and being drawn in by the cosmos.

“I always knew I would end up doing something in space technology,” he says.

In 2019, he was selected for Project PoSSUM (Polar Suborbital Synthesis in Upper Mesosphere) by the International Institute for Astronautical Sciences (a formerly  NASA Space Flight Opportunities aided research program). Post his training, he worked on commercial spaceflight program planning.

During the COVID-19 pandemic in 2020, he joined ISRO (Indian Space Research Organisation) as a research associate and worked on programs related to human space life support.

At ISRO, Shubhayu Sardar was appointed as his mentor.

At the time, Shubhayu had been working as a scientist at ISRO for more than 9 years. Having contributed to PSLV and GSLV missions, he was one of the first engineers to be part of India's human space flight mission, Project Gaganyaan.

“Shubhayu and I clicked immediately. Being his mentee was an extremely enriching experience,”Manu tells Startup Pedia.

Later in 2021, Manu J Nair joined an IIT Bombay-based space company, Manastu Space.

“Here, I met Prashanth Sharma. He is a college dropout and is genuinely a prodigy. He was heading the propulsion division at Manastu Space at the time. We became friends,”Manu shares.

One night over dinner in Bengaluru, he introduced Shubhayu and Prashanth to each other.

The three discussed their passions for space and what drove each of them to consistently innovate and contribute to the field. 

During the conversation, the topic of space missions being incredibly expensive came up.

“We realized that the costs add up primarily because rockets burn up and can't be used again. Getting to space is a difficult affair. Additionally, there is a global market dependence on a single launch vehicle. Some companies still try to reuse the rocket’s booster, but not the upper part. Because it keeps burning up, the amortised cost per kilogram never makes sense until you are vertically stacked.” Manu J Nair tells Startup Pedia.

And just like that…Shubhayu Sardar, Manu J Nair, and Prashanth Sharma decided to start EtherealX as a space technology company that builds fully reusable rockets and tangibly brings down launch costs.

“It happened so organically, but felt so right. Everything was more than just aligned,”Manu remarks.

In May 2022, EtherealX was officially founded and established.

EARLY JOURNEY AND CHALLENGES 

Initially, the founders started EtherealX by pooling their savings of 15,000 USD.

The first six to seven months were spent conducting intense market research and understanding the main problem areas to be addressed.

“Our mission was simple: convert the space launch market from a unipolar one into a multipolar one,” space entrepreneur Manu mentions.

For the first year, they did not hire anyone and simply worked on the engineering challenges, building the physics, and computer simulations themselves.

“Not to glorify it, but we had crazy working hours back then. Coming into the office at 10 AM, leaving at 7 PM, and then coming back at 11 PM. But we enjoyed every bit of it. It was just hoodies, shorts, coffee, and simulations,” Manu J Nair shares.

It was in January 2023 that EtherealX hired its first two interns.

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ETHEREALX: BRINGING BACK ENTIRE ROCKETS LIKE NO ONE ELSE

At EtherealX, the space startup founders are building fully reusable rockets. This means both the lower and upper stages of the rocket return safely after the launch and can be reused again.

This is the first time that this innovation has been completely achieved in the global space launch industry.

“Even the only operational orbital class reusable launch vehicle operator, for that matter, doesn’t recover the upper stage, which actually carries the satellite into orbit. It is both a technology challenge as well as a unit economics problem.”space startup founder Manu J Nair says.

So, how has EtherealX managed to solve this problem?

• The space technology startup has built a new rocket engine feed cycle that powers and manages fuel flow in a rocket.

EtherealX’s engine design has been made in a way that helps control reentry heat and makes upper-stage recovery entirely possible. 

• Instead of utilizing heavy and expensive heat shields to protect the upper stages from burning on reentry, EtherealX has developed technology that redirects heat using their engine system. 

“What this does is enable the upper stage of the rocket to slow down, survive reentry, and land,” Manu tells Startup Pedia. 

EtherealX’s space entrepreneurs and engineers have developed a reusable medium-lift launch vehicle called the Razor Crest Mk-1. 

Its payload capacities vary by mode. For instance, it can carry up to 24.8 tonnes into the Lower Earth Orbit (LEO) and up to 10.8 tonnes into the Geosynchronous Transfer Orbit (GTO in its expendable mode). 

Razor Crest Mk-1’s upper stage is powered by the Pegasus engines, each of which generates 40 kN thrust.

With this, EtherealX has developed India's first reusable medium-lift rocket and the world's first rocket system with full reusability. 

“Think of it as an airplane. It does what it is supposed to and comes back to do the same the next time around. That's what we've envisioned for rockets at the Guild,”space entrepreneur Manu J Nair explains.

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GROWTH AND IMPACT

The space technology company promises two tangible benefits. 

First, launching satellites will become significantly cheaper. Second, global dependence on one company would be reduced. The unipolar market would be prevented from becoming a monopoly, and a competitive, affordable alternative would be available. 

According to the space startup founders, by 2027, EtherealX will be live with its Technology Demonstrator Vehicle (TDV). It will be able to assist affordable launches that will range from $350 to $2000 per kilogram.

To date, EtherealX has received roughly $100K in grants from institutions like Startup India and Elevate Karnataka. 

Last year, the space startup founders also raised $5 million in a funding round that was led by YourNest, a deeptech-focused VC firm. The round also saw participation from the likes of BIG Global Investments, BlueHill Capital, Campus Fund, and Golden Sparrow Ventures.

“Four years ago, if you had asked us if we saw ourselves starting a rocket company, we would've said no. Each of us had our own thing going, but we were meant to work together on creating something that changes the face of how we look at and handle space launches today. EtherealX is consistently doing just that,”Manu J Nair signs off. 

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