Filament-wound composite motor casings, shrouds and adapters likewise were also examined for cost advantages to the ALS by increasing strength and performance while reducing weight. Automation would cut the present high cost of fabricating composite structures, and robotics might be applied to plasma arc welding and other processes effectively, even in relatively low rate production. ALS managers explored a variety of launch operations concepts, including horizontal processing, new launch complexes and improved manufacturing, systems integration, and checkout procedures. The Air Force has stated that such a lift capability was primarily be required to launch elements of a ballistic missile defense system and to alleviate payload design weight constraints. The Air Force estimated that the ALS would be capable of 20 to 30 flights per year after 1998.
Commercial aircraft use a similar safety feature.
Thus the Bush Administration inherited a plan for development of the Advanced Launch System that called for the Defense Acquisition Board to approve advanced development of the system in early 1990, leading to a first flight in 1998 and a full operational capability in 2000. However, by late 1989 it had become increasingly apparent that the requirements for the ALS program had largely disappeared. These vehicles would provide the capability to meet requirements from the heaviest to the smallest payloads.