Budget constraints and technical challenges delay commercial crew

A NASA inspector general report released today cites both budget constraints imposed by Congress as well as technical challenges that will delay the first commercial manned mission to ISS until 2018.

When the commercial crew program began, NASA hoped to have routine flights by 2015, but that slipped in large part due to congressional underfunding in the early years. OIG noted today that its 2013 report found that adequate funding was the major challenge for the program. Congress has warmed up to the program, however, and now is approving the full President’s request so funding is not the issue it once was. Technical challenges now are the major hurdle according to today’s report.

The companies’ systems must be certified by NASA before beginning routine flights to ISS. Boeing anticipates receiving certification in January 2018 with its first certified flight in spring 2018, and SpaceX is working toward late 2017 for its first certified mission, the OIG report says. But it is skeptical: “Notwithstanding the contractors’ optimism, based on the information we gathered during our audit, we believe it unlikely that either Boeing or SpaceX will achieve certified, crewed flight to the ISS until late 2018.”

The report has been written prior to yesterday’s Falcon 9 launchpad failure, which will certainly impact the schedule negatively.

Essentially, the report claims that the program was delayed initially by about two to three years because of the refusal of Congress to fund it fully. The delays to come will be instead because of the technical challenges. While I tend to agree with this assessment, I also note that government reports like this are often designed to generate more funds for the agencies involved, not find a better way to do things. If we are not diligent and hard-nosed about how we fund this program I worry that with time commercial crew will become corrupted by the government’s sloppy and inefficient way of doing things, and become as bloated as Orion and SLS. This is one of the reasons I never complained when Congress short funded the program previously, as it forced the companies involved to keep their costs down.

Falcon 9 explodes on launchpad

During a standard prelaunch static test firing today a Falcon 9 rocket exploded on the launchpad.

Obviously, this will put a hold on all of SpaceX’s upcoming efforts.

  • Falcon Heavy: Since the explosion was almost certainly caused by a failure in the first stage, they will have to hold off that first Falcon Heavy demo launch scheduled for this fall, since it uses three first stages strapped together.
  • Reused Falcon 9: Similarly, the first launch of a recovered Falcon 9 first stage, also set for the fall, will likely have to be delayed until they determine what went wrong today.
  • Reused Dragon: NASA had indicated that one of the cargo missions to ISS next year would reuse a previously flown Dragon. Though this explosion has nothing to do specifically with Dragon, the capsule is launched with a Falcon 9, and thus cannot fly until this investigation is over.
  • Falcon 9: SpaceX had been attempting this year to up its launch rate to more than one per month. That will now not happen.
  • Red Dragon: SpaceX has said it plans to fly a test Dragon to Mars in 2018, the next launch window. While this explosion will delay the company’s plans over the next year, I expect SpaceX will not cancel that 2018 launch. They have enough time to investigate this failure and fix the cause without missing that window.
  • Elon Musk’s Mars speech: Finally, Musk is scheduled to make a major speech on September 26 at the International Aeronautical Congress (IAC) in Guadalajara, Mexico, outlining his company’s future plans to fly to Mars. He almost certainly will have to rewrite that speech.

This launchpad explosion is bad news for SpaceX but it is also very puzzling. I cannot remember the last time a rocket exploded on the launchpad during a static fire test. Failures have in recent years always occurred during the actual launch, when the rocket is flying and is thus exposed to large dynamic forces which can cause the engineering to go screwy. For a rocket to explode at the moment it ignites its engines suggests a very fundamental design fault, which seems unlikely considering the number of launches and static fires SpaceX has completed with the Falcon 9, including numerous prelaunch tests of the rocket’s first stage, both on the launchpad and at the company’s test facility in Texas prior to shipment to the launchpad.

Update: SpaceX has now said that the problem occurred near the rocket’s upper stage during fueling, prior to the actual ignition of the engines.

This news is both good and bad. The good news: It means that the failure had nothing to do with the much tested Merlin engines, which would have suggested a fundamental design flaw previously unseen. That is now clearly not the case. The bad news: The update suggests that the problem might be related to SpaceX’s high density, high pressure fueling, which by lowering the temperature of the tanks allows them to load more fuel and oxidizer. This novel approach, only introduced last year in order to give the rocket greater fuel capacity, might have a design problem that they had not anticipated.

Big scandal for Virgin Galactic’s investment partner

Virgin Galactic’s biggest investor has been caught up in a big scandal involving two of its top managers, including the arrest of one.

As noted at the link, there is no evidence that anyone at Virgin Galactic was involved in what appears to be an illegal transfer of $3.5 billion from the investment company. However, the collapse of this company, which invested $390 million for a 37% share in Virgin Galactic, could impact the space company’s future efforts.

DNA sequencing successfully done on ISS

Researchers have now confirmed that a new lightweight DNA sequencer has been successfully tested on ISS.

Using a hand-held, USB-powered sequencing device called the MinION, astronaut Kate Rubins, PhD, sequenced samples of mouse, bacteria and virus DNA. This portable sequencing technology could eventually help diagnose sick astronauts, monitor space station food, water, and environment for microbes, and identify extraterrestrial life forms.

As part of a collaboration with NASA on the Biomolecular Sequencer project, Earth-bound researchers – a bicoastal team at UCSF and Weill Cornell Medical College – analyzed the sequencing data from space and compared it to identical samples sequenced on the ground. The analysis would tell whether the journey to space and conditions aboard the space station affected the sequencing results.

…[An] analysis of the space and Earth data found comparable results. “We essentially got equivalent data, and it’s of very high quality, probably within the top 20 percent of nanopore runs that we do routinely here on Earth,” Chiu said.

The press release makes a big deal about how this new equipment will be beneficial for research in space, but I am betting that its creators are as much if not more interested in the profits they will make selling it to customers on Earth, where its portability will make a very useful and beneficial to Earth-bound patients and researchers.

Third Lunar X-prize competitor signs launch contract

The competition heats up: The Google Lunar X-prize has confirmed that a third competitor, Synergy Moon, has signed a launch contract to send its privately built and funded rover to the Moon.

The Synergy Moon mission will use a Neptune 8 rocket, built and launched by Interorbital Systems, to carry a lunar lander and at least one rover to the surface of the moon, launching from an open-ocean location off the California coast during the second half of 2017. Team Synergy Moon is one of three Google Lunar X-Prize teams now set to compete in 2017, joining SpaceIL and Moon Express. The remaining 13 teams have until December 31, 2016 for their launch agreements to be verified by X-Prize in order to proceed in the competition.

In looking at the website of the launch company, I am not impressed. I hope they succeed, but I would not put much money on this Lunar X-Prize competitor.

World record for largest 3D printed object

Oak Ridge National Laboratory has entered the Guinness record books with the successful printing of the world’s largest 3D printed object.

Made from carbon fiber and ABS thermoplastic composite materials, the new tool measures 17.5 x 5.5 x 1.5 ft (5.3 x 1.7 x 0.5 m) and weighs around 1,650 lb (748 kg). To meet the requirements of the record, the item needed to be one solid piece of 10.6 cubic ft (0.3 cubic m), which a Guinness World Records judge confirmed at a ceremony. “The recognition by Guinness World Records draws attention to the advances we’re making in large-scale additive manufacturing composites research,” says Vlastimil Kunc, leader of [Oak Ridge] team. “Using 3D printing, we could design the tool with less material and without compromising its function.”

Of course, the tool wasn’t designed just for world record glory: printable in just 30 hours, it’s an impressive time and cost saver, considering the existing metal version currently takes about three months to manufacture. [emphasis mine]

The highlighted text illustrates in one sentence why there is a push toward 3D printing. It is cheaper, faster, and will eventually provide much greater flexibility.

First relaunch of Falcon 9 1st stage announced

The competition heats up: SpaceX and the Luxembourg satellite company SES today announced that the of SES 10 this fall will use one of the Falcon 9 first stages that has flown previously and been recovered. From the SES press release:

“Having been the first commercial satellite operator to launch with SpaceX back in 2013, we are excited to once again be the first customer to launch on SpaceX’s first ever mission using a flight-proven rocket. We believe reusable rockets will open up a new era of spaceflight, and make access to space more efficient in terms of cost and manifest management,” said Martin Halliwell, Chief Technology Officer at SES. “This new agreement reached with SpaceX once again illustrates the faith we have in their technical and operational expertise. The due diligence the SpaceX team has demonstrated throughout the design and testing of the SES-10 mission launch vehicle gives us full confidence that SpaceX is capable of launching our first SES satellite dedicated to Latin America into space.”

I also like how they call the used first stage “flight-proven.” This story notes that the insurance cost for the launch weren’t raised either.

The exact date has not yet been set, but it will be in the fourth quarter of 2016.

Concrete poured for Blue Origin factory

The competition heats up: Blue Origin this week began pouring concrete for its new rocket factory in Florida.

The Florida facility will be devoted to orbital operations, involving a spacecraft currently known as “Very Big Brother.” The orbital craft could eventually be offered to NASA as a transport ship for cargo or astronauts flying to and from the International Space Station. It could take on other missions as well.

They hope to open the facility by 2018.

Dragon splashes down

The competition heats up: SpaceX’s most recently launched Dragon capsule today returned to Earth and was successfully recovered.

The Dragon is the only spacecraft flying today that can return large amounts of cargo to Earth.

Among the cargo brought back from space Friday were a dozen mice from a Japanese science experiment — the first brought home alive in a Dragon. Samples from mice euthanized as part of an experiment by pharmaceutical company Eli Lilly also were on board. Results were returned from an experiment that studied the behavior of heart cells in microgravity, and from research into the composition of microbes in the human digestive system, NASA said. Findings from both could help keep astronauts healthy during deep space exploration missions.

Starliner and Orion drop tests

The competition heats up: NASA and Boeing have begun drop tests on land and water respectively of their Orion and Starliner manned capsules.

Both sets of tests are taking place at Langley. With Orion they are dropping the mockup in water to test how it will respond to a variety of circumstances. With Starliner they have finished the water drop tests and have begun drop tests on land.

Chinese company agrees to buy Israeli satellite company

Wheels within wheels: A Chinese company, managed by a Luxembourg company that in turn delegates management of its satellites to an Israeli-based company, has made a deal to purchase Spacecom, a different Israeli company that operates and owns the Amos fleet of communications satellites.

Observers said the deal could meet up with opposition from regulators, including the Communications Ministry. But Pollack said the transaction would be done in accordance with Spacecom’s license terms, which require the satellites be operated from Israel and that the company remain Israeli. The sale would put Spacecom under the direct control of an Israeli-domiciled company called Big Bird, which is managed by Major General (Res.) Ami Shafran, a former head of the Israel Defense Forces communications branch. Big Bird is 100%-owned by a Luxembourg company, which in turn is owned by Beijing Xinwei.

To say this financial deal is complicated is to understate the situation. Though it appears most everyone here is probably focused on making money, if I was Israeli I would be somewhat concerned that ownership of these crucial communications satellites is now going to be outside the country.

I also note the presence of Luxembourg in this space deal, illustrating again that this small European country is very much a big player in the commercial space industry.

Virgin Galactic, an expert in diversity!

Private vaporware: Virgin Galactic can’t seem to get its SpaceShipTwo off the ground but, darn it, the company, in partnership with the International Symposium for Personal and Commercial Spaceflight (ISPCS), sure can run a diversity workshop!

While charging each attendee $500 for the privilege! This quote from the link above illustrates where Virgin Galactic appears to be placing its focus:

Virgin Galactic’s Executive Vice President of Spaceport and Program Development, Jonathan Firth, recently spoke to us about the industry’s need to expand behaviours and devise new ways to embrace a more diverse and inclusive workforce. “Presently only 16 per cent of the space industry workforce are female. In order to strengthen our industry and our chances of achieving great things long term we need to change this. We need to refocus on how crucial it is that we, as a company, an industry, a planet, are proactively encouraging a wide ranging of workforce from all walks of life, geographical locations, academia, gender and race. We’re sure that the event will share some incredibly informative and surprising truths about why some teams thrive and others falter,” said Jonathan.

Then there’s this quote from this news report about the workshop:

Lastly, Virgin Galactic and the ISPCS ask the public to consider “What does success look like, without self at the center?”

To me, success for a space tourism company is flying its ships and passengers in space, not spending its time focusing on the race and gender of its employees. So far, it appears that Virgin Galactic does not yet understand this.

Unknown new British company will fly space tourists in five years

Private vaporware: A new and previously completely unknown British rocket company, Starchaser, has claimed today that it will be flying tourists into space within three to five years.

How do I know this is vaporware and won’t happen? Besides the fact that I’ve never heard of this company before and that the story above includes a lot of fishy details (such as the head of the company has apparently most spent his time building large model rockets), there was this one quote:

The flight will only take an hour and will see the rocket reach around 330,000ft – ten times the average cruising altitude for an aeroplane flight.

An hour is too short for an orbital flight, and is much too long for a suborbital flight at 330,000 feet. In other words, something here is just not right. Regardless, I hope my cynicism here turns out to be wrong, and this company joins the new competition to lower costs into space.

The world’s longest and highest glass-bottomed bridge

Link here. Lots of great pictures of this new pedestrian bridge in China, including one of a reporter trying (and failing) to use a sledge hammer to break the glass.

China’s economy might have a lot of holes and might face collapse, as many experts have been telling me for years, but at the same time they seem to be successfully harnessing the success they’ve had in the past few decades to get very creative. That creativity suggests to me the collapse is not guaranteed, and will not be as severe as predicted.

More reasons why I don’t use Windows

A close look at Microsoft’s track record in rolling out Windows 10 suggests the company “blatently disregards user choice and privacy.”

After describing the numerous horror stories of how Microsoft forced Windows 10 updates on people against their will, there was this:

The trouble with Windows 10 doesn’t end with forcing users to download the operating system. Windows 10 sends an unprecedented amount of usage data back to Microsoft, particularly if users opt in to “personalize” the software using the OS assistant called Cortana. Here’s a non-exhaustive list of data sent back: location data, text input, voice input, touch input, webpages you visit, and telemetry data regarding your general usage of your computer, including which programs you run and for how long.

You do have to opt-in to Cortana, but even if you don’t, your privacy is still not secure:

And while users can disable some of these settings, it is not a guarantee that your computer will stop talking to Microsoft’s servers. A significant issue is the telemetry data the company receives. While Microsoft insists that it aggregates and anonymizes this data, it hasn’t explained just how it does so. Microsoft also won’t say how long this data is retained, instead providing only general timeframes. Worse yet, unless you’re an enterprise user, no matter what, you have to share at least some of this telemetry data with Microsoft and there’s no way to opt-out of it. [emphasis in original]

It is once again time for people to consider alternatives. Here again are the links to James Stephens’ series on Behind the Black for Getting and Installing Linux:

Lots of launches

The competition heats up: The next few weeks will be a busy period for rocket launches:

SpaceX’s September 3 launch is part of their effort to ramp up their launch rate and get 18 Falcon 9 launches in 2016. So far they have completed 8 launches.

The September 8 launch will be the United States first sample return mission to an asteroid, Bennu, which also happens to be an asteroid that could possibly impact the Earth at some time in the future.

The September 10 launch will be another test flight of India’s more powerful Geosynchronous Satellite Launch Vehicle, aimed at competing for launch business against SpaceX, ULA, and Arianespace.

There’s more beyond this. A lot is scheduled for this fall.

SpaceX to up its purchase of carbon fiber?

The competition heats up: A Japanese supplier of carbon fiber materials has announced that it and SpaceX are negotiating a multi-year deal worth possibly as much as $3 billion.

The multiyear deal with Tesla founder Elon Musk’s 14-year-old venture is estimated to be worth 200 billion yen to 300 billion yen ($1.99 billion to $2.98 billion) in total. The two sides are aiming to finalize the agreement this fall after hammering out prices, time frames and other terms. SpaceX aims to hold down expenses by re-using rockets and spacecraft. Originally, the company made rockets mostly out of aluminum to keep costs low, using carbon fiber only for a few parts, such as connecting joints.

The U.S. company said in a statement, “Toray is one of a number of suppliers we work with to meet our carbon fiber needs for Falcon rocket and Dragon spacecraft production, and we haven’t announced any new agreements at this time. As our business continues to grow, the amount of carbon fiber we use may continue to grow.”[emphasis mine]

The deal is not yet final, but the highlighted language above suggests to me that, based on SpaceX’s engineering tests of its recovered first stages, it has decided it is worthwhile replacing aluminum with carbon fiber for many more of its rocket parts. The fiber might cost more, but if the first stage is going to be reused, the cost can be distributed over several launches. And because carbon fiber is lighter than aluminum, it will allow their rockets to launch a larger payload.

More evidence ULA will pick Blue Origin over Aerojet Rocketdyne

In a press interview published in late July, a ULA executive confirmed that the company is going to pick Blue Origin’s BE-4 engine for its new Vulcan rocket.

ULA used a Russian engine for its expendable Atlas V booster but has long relied on U.S. suppliers such as Aerojet Rocketdyne. For Vulcan’s reusable engine, ULA is turning to Jeff Bezos’s Blue Origin. The company’s cutting-edge BE-4 is powered by liquid natural gas instead of kerosene or liquid hydrogen.

By partnering with a startup like Blue Origin, ULA gains other advantages. “There is a world of difference between the culture at Blue Origin and the culture at Aerojet Rocketdyne,” said [Dr. George F. Sowers, ULA’s vice president for advanced programs]. “We knew we could absorb some of their culture by osmosis, just by working with them.” That influence shows up in cross-team collaboration. “We are literally breaking down walls to create a ‘Silicon Valley’ workspace,” Sowers said.

Sowers is very careful to say nothing about the Atlas 5 and the engine that will replace the Russian engine in its first stage. ULA originally signed its deal with Blue Origin with the Atlas 5 in mind, but has not made a final decision between Blue Origin and Aerojet Rocketdyne because Congress appears to favor Aerojet Rocketdyne’s engine, and Congress is a very big gorilla you do not upset. However, their development plans for Vulcan are incremental and closely linked with the Atlas 5. They plan to introduce Vulcan piecemeal in various upgrades of Atlas 5 as they go, so if they are set on using Blue Origin’s engine in the Vulcan rocket, it probably means that they plan on using it to replace the Russian engine in Atlas 5. This interview appears to confirm this.

Russia’s space station faces funding problems

The Russian space station replacement for ISS, dubbed the Russian Orbital Station (ROS), faces serious budget problems that might delay its launch.

Plans for the post-ISS Russian Orbital Station, ROS, are in limbo, as the nation’s space program has faced budget cuts in 2016. Although the industry has now completed formulating the overall design of the future station, the cash-strapped Roskosmos was yet to approve the formal technical assignment for the development of ROS as of June 2016. The addendum to the Federal Contract, which would fund further development work on the project, has not been issued either.

The ROS project stalled despite being formally approved by three strategy documents governing the current Russian space program: The 10-year Federal Space Program from 2016 to 2025, known as FKP-2025; The Strategy for Russian Piloted Space Flight until 2035 and the Concept of the Russian Piloted Space Flight.

The article also provides a nice overview of how Russia hopes to assembly ROS, partly from new modules and partly from modules they will detach from ISS. The article also made this key point:

According to the current ROS concept, the new Russian station will have a truly unlimited life span, thanks to the possibility to replace any of its modules. (It is practically impossible with the current ISS architecture.) The new Russian station is also designed to operate either as a permanently inhabited outpost or as a periodically visited facility. Russian strategists also hope that the new station will inherit the international nature of the ISS project.

I think Russia is beginning to see the operation of Earth orbital space stations as a profitable niche they can occupy. They know how to do it and already have the technology on hand, and can do it at very affordable prices. Whether they can afford it themselves, however, remains an open question.

Aerojet Rocketdyne gets NASA contract for cubesat engine

The competition heats up: Aerojet Rocketdyne has signed a contract with NASA to develop a small thruster engine for use on cubesats.

The MPS-130 green propulsion system will allow CubeSats and SmallSats to increase their capabilities, such as extending mission life, increasing architecture resiliency, maneuvering to higher and lower orbits, and performing complex proximity operations and formation flying. The use of additive manufacturing also reduces the number of parts and amount of time required to fabricate and assemble the modular propulsion system, lowering the cost of small satellites for private and public operators. Under the contract, Aerojet Rocketdyne will deliver a fully-integrated MPS-130 green modular propulsion system for flight demonstration, as well as conduct development and validation testing.

The press release does not say how much money NASA is providing. Regardless, this is a great opportunity for Aerojet Rocketdyne, because the smallsat industry is I think about to take off, and at the moment these tiny satellites lack any useful technology for maneuvering. Up until now they were mostly designed as temporary short term satellites built mostly to teach students. Soon, however, there will be a lot of privately-built commercial smallsats launched, designed to make money. Being able to sell their builders a thruster that could prolong their life and make them more capable will give Aerojet Rocketdyne a product that will certainly sell like hotcakes.

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