HOUSTON, WE HAVE A PROBLEM

SpaceShipTwo Flew on Untested Rocket

Richard Branson’s plane meant to carry tourists into space never tested a new engine using new fuel before it flew—and exploded—over California on Friday.

10.31.14 8:05 PM ET

Virgin Galactic’s SpaceShipTwo crashed in the California desert Friday after testing a new rocket motor for the first time in flight. The company said an “in-flight anomaly” occurred. Law enforcement said one pilot was killed and the other was seriously injured.

“During the test, the vehicle suffered a serious anomaly resulting in the loss of the vehicle,” Virgin Galactic said in a statement it released to NBC News. “Our first concern is the status of the pilots, which is unknown at this time. We will work closely with relevant authorities to determine the cause of this accident and provide updates as soon as we are able to do so.”

SpaceShipTwo had been slung under the jet-powered carrier aircraft WhiteKnightTwo before taking off. WhiteKnightTwo carried SpaceShipTwo to 50,000 feet before releasing it for free flight.

The Federal Aviation Administration provided additional details on what happened next.

“Just after 10 a.m. PDT today, ground controllers at the Mojave Spaceport lost contact with SpaceShipTwo, an experimental space flight vehicle,” FAA spokeswoman Laura Brown told The Daily Beast in an email. “The incident occurred over the Mojave Desert shortly after the space flight vehicle separated from WhiteKnightTwo, the vehicle that carried it aloft. Two crew members were on board SpaceShipTwo at the time of the incident.”

The WhiteKnightTwo remained airborne after the incident and landed safely.

The National Transportation Safety Board also will investigate the crash, a spokesman told The Daily Beast.

SpaceShipTwo was testing a new plastic-based rocket fuel for the first time Friday. An eyewitness told The Daily Beast that the spacecraft exploded shortly after the rocket motor was ignited. The spaceship had not flown a powered flight in about nine months because engineers were switching out its original engine that used rubber-based rocket fuel for the new engine, which used plastic-based fuel.

Scaled Composites, which built the spacecraft, had experienced some problems with the new rocket, which until Friday had only been tested on the ground. While the new motor holds much promise of greatly increased performance, there were some serious risks associated with the new rocket—as Friday’s incident proved.

With the new rocket installed, SpaceShipTwo was expected to fly more than five times higher than it had ever flown before—right to the edge of space at 62 miles above the Earth. In some ways, SpaceShipTwo, which was to reach a maximum speed of about 2,500 miles per hour during its ascent into space, was pushing the limits of its virtually untested design.

It was not the first time Virgin pushed limits to get into space. A new biography about SpaceShipTwo’s patron, Richard Branson, by investigative journalist Tom Bower makes that clear. Rocket engineers Geoff Daly and Caroline Campbell were critical of one of the components of the original rubber-based fuel: nitrous oxide. Campbell warned: “Nitrous oxide can explode on its own.” Another toxic component of the fuel was hydroxyl-terminated polybutadiene, a form of rubber. Campbell said that when the engine ran there was “so much soot coming out the back, burning rubber, that it could be carcinogenic.”

In 2007, the unattached rocket engine using that fuel was being tested on the ground in the Mojave desert when it exploded and killed three of 40 engineers observing the test. Investigators found that safety regulations at the site had been violated and that the men killed had been too close to the rocket motor.

After tests this January, it was decided to the fuel powering the rocket engine should have its rubber removed. The reason was not toxicity but that the fuel did not provide consistent and stable power, and the test pilots had to shut down the engine prematurely. Before SpaceShipTwo could fly with the new fuel aboard it had to be extensively tested on the ground. As those tests were taking place, Branson told Bloomberg TV: “It took us a lot longer to build rockets that we felt completely comfortable with.”

SpaceShipTwo was expected to usher in a new era of commercial space travel: More than 700 people had already paid more than $250,000 each for a chance to leave the planet and experience the weightlessness of space flight. Branson himself had been planning to fly onboard the spacecraft by next year.

Friday’s incident, however, throws all of that into question.