Comment by ordinaryradical

Source: worked at a startup that took over the patents for the X-33 next gen shuttle and VentureStar SSTO (aerospike design!)

The Columbia disaster really set back SSTO appetite. Probably the whole reason we got the patents, truly.

SSTOs are, like everything else going to orbit, delimited by weight.

If you are going to make the fuel tanks internal to the vehicle and not something that falls off and sheds their weight mid-flight, you have to get vehicle weight to the absolute minimum. Losing weight has second order effects because it means you now have to carry less fuel so you now have a smaller fuel tank which means the tank weighs less which means you get to carry less fuel… etc.

The key, IMO, is material science advancements, specifically around plastics and composites. Very efficient engine design is matters too, but if you can just bring less mass up with you you can start to approach an achievable fuel weight.

It’s a hard job, you need plastics that can handle orbital temperature cycling (+300 to -300 F every 30 mins), atomic oxygen (nasty corrosion), UV with no atmospheric protection, FST for crew exposure…

Exotic metal alloys can get you around some of these problems, but they can be difficult and expensive to work with. Same issue with high-performance polymers. No free lunches here.

With 3D printing of metals and high-performance composites, you can probably remove additional weight so there’s some light in that tunnel.

But all in all it’s very hard to get out of the gravity well with your fuel in tow and survive the extremes of space. My belief is the first vehicle to pull it off will look like a Swiss cheese of voids and lattices from printing / honeycombs and be made almost entirely out of plastic and carbon fiber.