Why do we still expect “successful failures” on rocket launches and not just scale up or scale down the same design on successful rocket ships and launch pads to make bigger or smaller ships with more stable structural material?

Question

Why do we still expect “successful failures” on rocket launches and not just scale up or scale down the same design on successful rocket ships and launch pads to make bigger or smaller ships with more stable structural material?

In: 1598

Answer 1

In addition to what others have said, full-up testing also reveal the weaknesses and assumptions in the calculations. Famously, an Apollo era Lunar Lander drop test had a leg collapse. Review showed a calculation for leg design had an error that crept through multiple design reviews unchallenged, and didn’t reveal itself until actual full size physical testing. This led to a wall-to-wall review of all the calculation assumptions being cross checked by other departments for validity and accuracy.