Economics
The expense of the fissionable materials required was thought high, until the physicist Ted Taylor showed that with the right designs for explosives, the amount of fissionables used on launch was close to constant for every size of Orion from 2,000 tons to 8,000,000 tons. The larger bombs used more explosives to super-compress the fissionables, reducing fallout. The extra debris from the explosives also serves as additional propulsion mass.
The bulk of costs for historical nuclear defense programs have been for delivery and support systems, rather than for production cost of the bombs directly (with warheads being 7% of the U.S. 1946-1996 expense total according to one study). After initial infrastructure development and investment, the marginal cost each of additional nuclear bombs in mass production can be relatively low. In the 1980s, some U.S. thermonuclear warheads had $1.1 million estimated cost each ($630 million for 560). For the perhaps simpler fission pulse units to be used by one Orion design, a 1964 source estimated a cost of $40000 or less each in mass production, which would be up to approximately $0.3 million each in modern-day dollars adjusted for inflation.
Project Daedalus later proposed fusion explosives (deuterium or tritium pellets) detonated by electron beam inertial confinement. This is the same principle behind inertial confinement fusion. However, theoretically, it might be scaled down to far smaller explosions, and require small shock absorbers.
Read more about this topic: Project Orion (nuclear Propulsion)
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