Tag: Orbital Reef

Sierra Space raises $550 million in private investment capital

9:01 am

Due to its aggressive shift in the past year away from NASA-based civilian contracts to defense work, Sierra Space announced yesterday that it has successfully raised another $550 million in private investment capital.

That shift occurred because of its failure to deliver its Dream Chaser vehicle to NASA as planned, as well as the apparently lack of progress in its partnership with Blue Origin on the Orbital Reef space station. From the press release:

Sierra Space Corporation, an industry-leading defense-tech space company delivering solutions for the nation’s critical missions, announced today a $550 million equity investment led by LuminArx Capital Management (“LuminArx Capital”), a global alternative investment manager, with participation from existing investors. The financing values the company at $8 billion post-money.

With this new capital, Sierra Space will be able to further focus on its national security space efforts through ongoing expansion of production capacity and continued development of differentiated solutions for its customers. The investment better positions Sierra Space to secure additional contracts, leverage existing technologies, and pursue growth opportunities beyond its current satellite and spacecraft mission programs.

Artist rendering of Orbital Reef design, as of April 2025
Artist rendering of Orbital Reef design, as of April 2025,
the best we can likely ever expect from this dead project.
Click for original image.

The release also mentioned General Atlantic, Coatue, Moore Strategic Ventures, and Andalusian Private Capital as investors.

Though this money should help fuel its work on Dream Chaser and Orbital Reef, I suspect little will go to those two projects. The company is now clearly targeting military and national security work as its prime source of income. There are also indications that there are some technical issues with Dream Chaser that Sierra has not yet revealed.

Meanwhile, the lack of effort from Blue Origin on Orbital Reef likely convinced Sierra it was better to turn its eyes elsewhere. While Sierra spent considerable effort testing its LIFE inflatable module, Blue Origin did practically nothing, and continues to do little. It is unlikely this partnership will win any funding from NASA when the agency awards new space station contracts, expected sometime in six months.

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NASA cancels Sierra Space’s contract for Dream Chaser cargo missions to ISS

8:01 am

Tenacity grounded in a warehouse
Tenacity grounded in a warehouse, with the
Shooting Star small cargo capsule attached to
its aft port.

NASA today announced it has modified its fixed-price cargo contract with Sierra Space, canceling the planned seven cargo missions as well as a demo docking mission, replacing this with one test flight that will simply go into orbit and then return to Earth.

After a thorough evaluation, NASA and Sierra Space have mutually agreed to modify the contract as the company determined Dream Chaser development is best served by a free flight demonstration, targeted in late 2026. Sierra Space will continue providing insight to NASA into the development of Dream Chaser, including through the flight demonstration. NASA will provide minimal support through the remainder of the development and the flight demonstration. As part of the modification, NASA is no longer obligated for a specific number of resupply missions, however, the agency may order Dream Chaser resupply flights to the space station from Sierra Space following a successful free flight as part of its current contract.

The first launch of Tenacity, the only Dream Chaser so far constructed, has been repeatedly delayed for the past two years, with no explanation from either the company or NASA. Those delays started in 2023 as engineers began the final ground testing before launch, so though we do not know what the issue is it is likely that testing found something fundamentally wrong with the spacecraft that Sierra could not afford to fix.

According to Sierra’s own press release, the company will target a late 2026 launch for that free flyer mission. The company still hopes that mission will make further flights possible, either purchased by NASA or by others wishing to use Tenacity for in-orbit manufacturing, something it first proposed last year.

In the past two years, Sierra has shifted its focus away from commercial manned space and more towards winning military defense contracts. Part of that decision might have come from the problems with Dream Chaser. The decision might have also been fueled by the company’s generally unsatisfactory experience working with Blue Origin on their proposed Orbital Reef space station. While Sierra committed cash to develop and test its LIFE inflatable module, including a full scale prototype, Blue Origin appeared to do nothing at all. As early as September 2023 there were rumors the partnership was falling apart.

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Space station startup Vast endorses NASA’s new strategy that no longer requires a continuous human presence in space

8:02 am

The American space stations under construction
The American space stations under development

Officials from the space station startup Vast revealed at a conference last week that they endorse NASA’s new strategy that, not only no longer requires the commercial stations to immediately establish a continuous human presence in space, will also award multiple development contracts to the commercial stations.

Speaking Sept. 11 at the Global Aerospace Summit, Max Haot [chief executive of Vast] endorsed NASA’s new strategy, announced more than a month ago, that calls for multiple Space Act Agreements to support development leading to a four-person, 30-day demonstration mission. “We think it’s really the right direction,” he said, noting it accelerates the award timeline. NASA said in a draft solicitation this month it expects to award multiple funded agreements by April 2026, months sooner than under earlier plans.

The original plan had been to choose at most two, but likely only one of the four consortiums/companies that are developing station proposals. The winner would have gotten a big contract that would have also required it to push hard for continuous full time occupation, from day one.

The new plan will instead award smaller development contracts to as many as three of the four station projects, aimed at getting them off the ground and operating, even if astronauts only fly in them intermittently. Eventually the hope is that their capabilities will expand quickly to permanent occupation, especially if they start earning revenue from the private sector, outside NASA. In fact, the smaller government contracts will force them to seek investment and profits elsewhere.

The four commercial stations under development, ranked by me based on their present level of progress:
» Read more

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Blue Origin completes ground simulation of Orbital Reef space station

9:16 am

Artist rendering of Orbital Reef design, as of April 2025
Artist rendering of Orbital Reef design, as of
April 2025. Click for original image.

According to a NASA press release today, Blue Origin has successfully completed a ” human-in-the-loop test” in a ground mock-up of the commercial Orbital Reef space station.

The human-in-the-loop test scenarios utilized individual participants or small groups to perform day-in-the-life walkthroughs in life-sized mockups of major station components. Participants provided feedback while simulating microgravity operations, including cargo transfer, trash transfer, stowage, and worksite assessments.

…The milestone is part of a NASA Space Act Agreement originally awarded to Blue Origin in 2021 and focused on the design progress for multiple worksites, floors, and translation paths within the station. This ensures a commercial station can support human life, which is critical to advancing scientific research in a microgravity environment and maintaining a continuous human presence in low Earth orbit.

Though this test might be providing useful information, it leaves me cold. While Blue Origin’s partner in this project, Sierra Space, has been testing real hardware for its LIFE inflatable module (as seen on the left side of the artist’s rendering above), Blue Origin itself appears to have built nothing real. Instead, it is following the old big space paradigm of companies like Boeing that invest none of its own money in development. Instead, the company uses NASA’s development money solely for PR mockups, in the hope the PR will convince NASA to give it the full contract, worth billions. Only then will the real work begin.

Boeing did this with Starliner, and we can all see now how well that turned out.

It also appears that the overall scale of Orbital Reef has been reduced significantly when comparing the current design above with the earlier artist renderings.

Based on this new information, I have dropped Orbital Reef to the bottom in my rankings of the four private space stations presently under development. While Starlab has built as little (following the same play-it-safe paradigm), the company has at least gotten its final design approved. It has also signed a partnership with the European Space Agency, giving it a powerful government backer in addition to NASA.

  • Haven-1, being built by Vast, with no NASA funds. The company is moving fast, with Haven-1 to launch and be occupied in 2026 for a 30 day mission. It hopes this actual hardware and manned mission will put it in the lead to win NASA’s phase 2 contract, from which it will build its much larger mult-module Haven-2 station..
  • Axiom, being built by Axiom, has launched three tourist flights to ISS, with a fourth scheduled for this spring, carrying passengers from India, Hungary, and Poland. Though there have been rumors it has cash flow issues, development of its first module has been proceeding more or less as planned.
  • Starlab, being built by a consortium led by Voyager Space, Airbus, and Northrop Grumman, with an extensive partnership agreement with the European Space Agency. It recently had its station design approved by NASA.
  • Orbital Reef, being built by a consortium led by Blue Origin and Sierra Space. Overall, Blue Origin has built almost nothing, while Sierra Space has successfully tested its inflatable modules, including a full scale version, and appears ready to start building its module for launch.
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Sierra Space signs deal using its Dream Chaser mini-shuttles for in-space manufacturing

10:33 am

Sierra Space's family of planned LIFE modules
Sierra Space’s family of planned LIFE modules. Click for original

Sierra Space has now signed agreements with two different startups, Astral Materials and Space Forge, to use its Dream Chaser mini-shuttles for in-space manufacturing.

Astral Materials leverages the microgravity environment of space to grow ultra-high quality semiconductor crystals for advanced chip technologies. Space Forge harnesses free flying manufacturing facilities to produce next-generation materials for commercial industries, national security and research.

Up to now, Sierra’s only customer has been NASA, which wants to use Tenacity, the first Dream Chaser mini-shuttle, to hauling cargo to and from ISS. These new deals illustrate that there are other profit opportunities for the company’s reusable shuttle outside of government. As the startup Varda has already demonstrated with its own returnable capsule, there is money to be made manufacturing products in weightlessness that cannot be produced in the gravity of Earth.

The press release however has one additional tidbit that is intriguing. Sierra is a partner in the Blue Origin-led Orbital Reef commercial space station. It also appears to be the only partner that is actually building anything for that station, specifically its LIFE inflatable modules. The press release mentions that both these agreements include options for Astral and Space Forge to provide “input on Sierra Space’s future space stations.” That this press release does not refer to Orbital Reef here suggests once again that Sierra Space is somewhat dissatisfied with the output of its Blue Origin partner, and is thus creating options for it to build its own space station using those LIFE modules (shown above), should Blue Origin not deliver.

At a minimum, Astral and Space Forge will certainly be interested in doing manufacturing within those LIFE modules, should they end up being part of Orbital Reef.

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Sierra Space announces plans to build a second Dream Chaser cargo spaceplane

2:58 pm

With the first launch of Sierra Space’s first Dream Chaser reusable unmanned cargo mini-shuttle, Tenacity, now scheduled for May 2025, the company has announced that it is beginning work on a second cargo spaceplane, dubbed Reverence, along with a mission control center to operate its fleet in orbit.

Sierra Space spokesperson Alex Walker shared the new May 2025 estimate and said work on Reverence, also known as DC-102, will resume once the team returns to Colorado — but declined to clarify when that would happen. At that point, Walker said, it will likely be another 18 months before the second spaceplane is complete. In addition to the fleet of cargo-carrying craft, Sierra Space is also working on a crewed variant of the vessel, labeled the DC-200 series, and a national security DC-300 variant.

Company officials say each mini-shuttle is good for 15 flights, so having both vehicles gives the company a total of 30 flights to sell to various space station and orbital customers.

Selling to others outside NASA may be necessary, because Tenacity is four-plus years behind schedule. By the time it begins flying ISS will already be approaching retirement in only a few short years.

The company intends these new Dream Chaser projects to work in tandem with its LIFE inflatable modules, which are presently being developed as part of the Blue Origin-led Orbital Reef space station. And while much of work on the rest of that station appears moribund, it appears that Sierra is developing everything needed for its own space station. We should therefore not be surprised if Sierra decides to bid on NASA’s next space station funding round independent entirely of the Orbital Reef partnership.

It certainly is assembling all the pieces needed for a station, without any help from Blue Origin.

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Sierra Space successfully completes 2nd test-to-failure of a full scale LIFE inflatable module

11:40 am

Sierra Space's family of planned LIFE modules
Sierra Space’s family of planned LIFE modules. Click for original

Sierra Space today announced it has completed a second successful test-to-failure of a full scale version of its LIFE inflatable module, intended for use not only on Blue Origin’s proposed Orbital Reef space station, but also available for purchase by other space station.

The latest test by the numbers:

  • Company’s second Ultimate Burst Pressure test of a full-size, inflatable space station structure occurred on June 18
  • Test unit stood over 20’ tall and was comparable in size to an average family home
  • The article was 300 m³ in volume, or 1/3rd the volume of the International Space Station
  • Test results exceeded NASA’s recommended x4 safety levels by 22%
  • Two 4-ft x 4-ft steel blanking plates were integrated into the highest loaded cylinder section of the article; both were 50 lbs. lighter than the ones used in the first full-scale test and accommodate larger windows

The test article in the company’s historic first full-scale burst test last December peaked at 77 psi, which well exceeded (+27%) NASA’s recommended level of 60.8 psi (maximum operating pressure of 15.2 psi multiplied by a safety factor of four). This most recent test in June showed similar results – within five percent of the pressure loading of December’s test article – with this one reaching 74 psi, exceeding NASA’s 4x safety factor by 22 percent. These back-to-back test results accelerate Sierra Space’s path to flight certification, verifying scalability for 10 cubic-meter and up to 1,400 cubic-meter structures based on the company’s current softgoods inflatable architecture. Sierra Space is currently gearing up for a first test of its 500 cubic-meter space station technology next year.

Video of this test, dramatically edited with its own music soundtrack, can be seen at the link.

It is intriguing that the only developments related to Orbital Reef appear to come from Sierra Space. From Blue Origin — supposedly the lead company in that project — we hear almost nothing. Though Sierra Space has said the partnership is still solid, it has also made it clear it is building the LIFE module not just for Orbital Reef. I think it is hedging its bets, anticipating that Orbital Reef will be another Blue Origin dud, and wants to market itself to others.

Hat tip to stringer Jay for this story.

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Japanese company proposes building a module to add to Axiom’s space station

9:24 am

Axiom's space station assembly sequence
The assembly sequence for Axiom’s space station while attached to ISS.
Click for original image.

The Japanese company Mitsui has now proposed building a module — based on Japan’s HTV cargo freighter that did several missions to ISS — and sell it to the commercial space stations now under construction.

Mitsui has created a subsidiary called LEO Shachu to develop the module. What makes this project very likely to happen is that Mitsui is also an investor in Axiom’s space station, and according to the article at the link, a Axiom official who is also a retired Japanese astronaut who flew to ISS has expressed interest in it.

This story also helps outline the international landscape of the future stations. While Voyager Space’s Starlab station has been partnering extensively with Europe and Airbus, Axiom appears to be partnering more closely with NASA and Japan. The third station that has obtained NASA money, Blue Origin’s Orbit Reef, had made an earlier deal with Mitsubishi, but appears to have obtained few other outside partners, and that Mitsubishi deal only involved “development work,” not specific hardware. Moreover, Mitsubishi later made a new deal with the Starlab station, suggesting it had broken up with Blue Origin.

A fourth station, being built by the private company Vast with no NASA money, has partnered with SpaceX and ESA. It is also likely to be the first to launch its first module in August 2025, followed soon thereafter by a 30 day 4-person Dragon mission.

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Sierra Space confirms burst test of its fullscale inflatable module was successful

9:21 am

Sierra Space yesterday confirmed that the pressure test-to-failure of a fullscale inflatable space station module was successful in proving its safety and design.

The pressure shell for Sierra Space’s LIFE™ (Large Integrated Flexible Environment) habitat is made of expandable “softgoods,” or woven fabrics that perform like a rigid structure once inflated. During an Ultimate Burst Pressure (UBP) test, the teams inflate the test article until it fails, which helps determine how strong its softgoods materials would be under extreme stresses in the harsh environment of space. The full-scale unit in this test reached 77 psi before it burst, which well exceeds (+27%) NASA’s recommended level of 60.8 psi (maximum operating pressure of 15.2 psi multiplied by a safety factor of four).

A short video showing the moment the module bursts can be seen here.

The module is for the Orbital Reef commercial space station that Sierra Space is building in partnership with Blue Origin, which is supposed to be the lead company in the project. However, it is Sierra Space that appears to be building and testing hardware. What Blue Origin is doing remains unclear, as has been the case now for five-plus years.

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NASA awards more money to two private space station proposals

10:34 am

Because Northrop Grumman has dropped its plans to build its own private space station, joining instead the Starlab station consortium led by Voyager Space, NASA has been able to shift the funding planned for Northrop Grumman’s station to two other two private space station projects.

Voyager Space’s Starlab station development will receive an additional $57.5 million from NASA, which brings NASA’s total funding for Starlab so far to $217.5 million, the space agency said.

…The Orbital Reef space station of Blue Origin and Sierra Space is receiving an additional $42 million, bringing that project’s total NASA funding so far to $172 million.

NASA says the extra money will help both consortiums meet their schedules.

A third private station, Axiom, also under development in partnership with NASA, plans to dock its initial modules to ISS, and then undock when completed to fly free.

A fourth American private space station is also being built, but independent of NASA entirely. The company, VAST, has teamed up with SpaceX to launch its first modules on Starship/Superheavy, followed by at least two manned missions.

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NASA updates status of three private space stations

8:58 am

NASA today posted a short update of the development status for the three private space stations for which it has signed contracts.

Not surprisingly, Axiom’s station appears to be the most advanced.

Axiom Space, which holds a firm-fixed price, indefinite-delivery, indefinite-quantity contract with NASA, is on schedule to launch and attach its first module, named Axiom Hab One, to the International Space Station in 2026. A total of four modules are planned for the Axiom Commercial Segment attached to the station. After the space station’s retirement, the Axiom Commercial Segment will separate and become a free-flying commercial destination named Axiom Station.

With the remaining two stations, Starlab and Orbital Reef, the update provided no schedule information. While both Starlab, being built by a consortium led by Voyager Space, and Orbital Reef, being built by a consortium led by Blue Origin, appear to be making progess, the former appears to be accomplishing more than the latter, though that impression could simply be what NASA decided to report. For example, in describing the work being done on Orbital Reef, NASA chose for some reason to say nothing about the testing Sierra Space has been doing to test the inflatible module planned for the station. By leaving that out it makes it appear as if less has been done in developing that station.

These are not the only private space stations being proposed, only the ones that have contracts with NASA. A fourth station, Vast, is being built using funding from private sources, and is partnering with SpaceX.

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Sierra Space shakes up its staffing

8:44 am

Sierra Space yesterday did a major staffing shake up, laying off 165 workers while shifting 150 with secruity clearances from its parent company Sierra Nevada.

Sierra Space this week shipped the first Dream Chaser, named Tenacity, for pre-launch testing at NASA’s Armstrong facility in Ohio. The layoffs began soon after, the Sierra Space spokesperson said, noting the company conducted a surge in hiring this year to complete work on the Tenacity spacecraft.

With Tenacity shipped, Sierra Space’s spokesperson said the company is realigning to focus on the operations phase of Dream Chaser’s first mission, as well as on classified national security work. The latter part of Sierra Space’s realignment includes adding nearly 150 employees with security clearances from Sierra Nevada Corp., the aerospace and defense contractor owned by Fatih and Eren Ozmen, which the space company was spun out of two years ago. Sierra Space’s spokesperson said the company is creating a national security space team to work on several classified contracts.

This shift suggests that at least in the short run, Sierra is putting more focus on future military contracts rather than its civilian manned space projects like its LIFE space module (for the Orbital Reef space station) and future manner versions of its Dream Chaser mini-shuttle. I wonder if the company is having more internal doubts about Orbital Reef and its main partner, Blue Origin. Unlike the stations being built by Axiom and Voyager Space, which have already garnered contracts from both national and international customers, Orbital Reef has not done the same. There could be great doubts in the space community it will be built because of Blue Origin’s absymal record for building anything.

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Orbital Reef partnership between Blue Origin and Sierra Space in trouble

9:36 am

According to anonymous sources, CNBC reports that the partnership between Blue Origin and Sierra Space to build the private commerical Orbital Reef space station is possibly breaking up.

The companies announced Orbital Reef as a co-led project in 2021, but updates about the project dried up in the past year. The pair of private space companies are now navigating a potential end to the Orbital Reef partnership, according to three people who spoke to CNBC about the situation.

Those people, speaking on the condition of anonymity to discuss nonpublic matters, emphasized that discussions are ongoing and described the situation as fluid. But other development projects with more significant current contracts – such as Blue Origin’s Blue Moon lunar lander and Sierra Space’s Dream Chaser spaceplane – have taken higher priority for both companies, those people said.

To readers of Behind the Black, this possible break-up is not a surprise. In June Sierra’s announcement of its own independent space station based on its LIFE modules suggested it had its own doubts about Orbital Reef. Then in August, when Sierra announced a partnership with Redwire to launch LIFE as an independent station, I wrote this:

What struck me about this deal is the shrinking mention of Blue Origin. Originally that company was listed as one of the major players in building this private space station, dubbed Orbital Reef, in which LIFE is only the first module. In the past year however its participation seems less and less significant in every subsequent press release. It appears to still be part of the project, but it is Sierra Space that is leading the effort, and appears to be making things happen.

But then, the track record of Blue Origin is to not make things happen. It could very well be that events are once again overtaking it. Sierra Space can’t wait for Blue Origin to slowly get its act together. It is finding ways to get things done, even if that means Blue Origin gets left behind.

Today’s CNBC story reinforces this conclusion. So does its timing with the removal of Blue Origin’s CEO, Bob Smith, earlier this week. It could be that the failure of Blue Origin in the Orbital Reef partnership was the final straw for Jeff Bezos.

The problem for NASA in this is that the agency awarded a $130 million contract to the Orbital Reef partnership, with Blue Origin listed as the lead contractor which controls the contract. If that partnership ends, that contract must get renegotiated or cancelled, or gets transferred from Blue Origin to Sierra Space (the most likely outcome).

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Redwire to build biotech lab in Sierra Space’s LIFE space station

9:38 am

Sierra Space announced yesterday that — as part of its private space station module dubbed LIFE — it is partnering with Redwire to install a commercial biotech lab in the module.

The hardware includes equipment that Redwire has previously developed for the International Space Station, such as the Advanced Space Experiment Processor, which hosts biotech experiments. A particular focus will be on crystallization experiments, using the microgravity environment to grow larger crystals that can then be studied to determine their structure for pharmaceutical applications.

The companies did not disclose terms of the contract other than that Redwire will start delivering hardware in the fourth quarter of this year. Gold said that the companies will also partner on business development to identify customers for using the experiment platform.

The target date for the launch of LIFE is presently 2026, though it was not revealed when Redwire’s equipment would be installed.

What struck me about this deal is the shrinking mention of Blue Origin. Originally that company was listed as one of the major players in building this private space station, dubbed Orbital Reef, in which LIFE is only the first module. In the past year however its participation seems less and less significant in every subsequent press release. It appears to still be part of the project, but it is Sierra Space that is leading the effort, and appears to be making things happen.

But then, the track record of Blue Origin is to not make things happen. It could very well be that events are once again overtaking it. Sierra Space can’t wait for Blue Origin to slowly get its act together. It is finding ways to get things done, even if that means Blue Origin gets left behind.

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Blue Origin negotiating with India to use its rockets and capsule for Orbital Reef space station

10:20 am

According to the head of India’s space agency ISRO, he has been in discussions with Blue Origin about using different versions of that nation’s largest rocket (dubbed LVM-3 or GSLV-Mk3 depending on configuration) and its manned capsule (still under development) for eventually ferrying crew and cargo to Blue Origin’s proposed Orbital Reef space station.

Somanath said: “We are exploring … In fact, we’ve already discussed it with Blue Origin and they are very keen to consider this option of LVM-3 becoming a crew capsule mission to service the Orbital Reef. It is a possibility and we are engaging through IN-SPACe (Indian National Space Promotion and Authorisation Centre).”

On the challenge of integrating a docking system that is compatible, he said standard docking systems are in the public domain. “…Whoever can design a docking system that matches with the US design and standard, can be used. However, we will still need to have agreements with agencies to try it out given that there are multiple interfaces — electrical, mechanical and so on. It is not just one document, we will need to work with them to develop it. We will do that.

It appears Somanath has also had discussions with NASA about also providing the same service to ISS.

An Orbital Reef deal however suggests something very disturbing about Blue Origin. The plan had been to use Blue Origin’s New Glenn orbital rocket (also still under development but years behind schedule) to launch crew and cargo capsules to the station. That in fact is supposed to be Blue Origin’s main technical contribution to the station. Why would the company then look to India for such capability, unless it recognizes that there are more problems with New Glenn that it has not revealed?

It is also possible that Jeff Bezos is simply expressing his leftwing globalist agenda with these negotiations. Or it could mean some combination of both. This situation bears watching.

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Sierra Space says first Dream Chaser will be ready for launch by December

12:41 pm

In a presentation at an investor conference on June 27, 2023, a Sierra Space official provided an update on the status of its first Dream Chaser reusable mini-shuttle, dubbed Tenacity, stating that they expect it to be ready for launch by December, with the main question whether its ULA Vulcan launch rocket will also be ready.

The launch is supposed to be the second for Vulcan, but the first launch was just delayed for an undetermined amount of time so ULA can make modifications to the rocket’s Centaur upper stage. Once Tenacity is flying Sierra has a contract with NASA for seven cargo flights to ISS, with plans beyond.

The company is also working on a second version that can carry both crew and cargo. Vice said that version will have 40% greater cargo capacity than the first version and can support a six-person crew.

The ability of Dream Chaser to glide back to Earth in a runway landing, rather than splash down in the ocean, is a key selling point to customers, he argued. “We just think that landing at runways around the world is a huge differentiator: low-g landing back on a runway for both time-critical cargo and science, but also just the way people are going to want to fly back and land.”

The official also indicated that this human-rated version is being designed to work with the private Orbital Reef space station that Sierra Space is building in partnership with other companies. The company also said it is planning its own free flying version of its Orbital Reef LIFE module that the company hopes to launch by the end of 2026, ahead of Orbital Reef. If so, that would make this the sixth independent private space station planned by American companies.

Because much of this presentation was designed to impress potential investors, we should take it with a touch of skepticism. Nonetheless, that the company is considering launching its own station, independent of the Blue Origin-led Orbital Reef station, suggests it has its own doubts about whether that project will ever take off as planned, and has thus decided to make its own contingency plans.

Hat tip to Jay, BtB’s stringer.

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Sierra Space pops another inflatable test space station module

9:56 am

Proposed Orbital Reef space station
Proposed Orbital Reef space station

Sierra Space announced yesterday that it had successfully completed its fourth test to failure of a one-third scale prototype inflatable space station module, dubbed LIFE, with work on the full scale module expected to begin next year and leading to the launch of its private commercial space station sometime later this decade.

In February, Sierra Space performed a month-long Accelerated Systematic Creep (ASC) test on LIFE – the first milestone in its 2023 testing campaign. Engineers loaded a one-third-scale version of the inflatable habitat with a sustained amount of pressure over an extended period until it failed. Per NASA’s recommended guidelines for inflatable softgoods certification, the test reached its goal of generating an additional data point – pressure and time to burst – which can be used to estimate the life of the primary pressure shell structure.

“Our testing campaign has demonstrated that our LIFE habitat pressure shell design has a predicted life of far greater than 60 years – or 525,600 hours – based on Sierra Space’s 15-year on-orbit life requirement and the applied 4x safety factor,” said Sierra Space Chief Engineer for LIFE, Shawn Buckley. “We are obviously simulating pressures well in excess of the norm.”

You can view video of the test here. The failure was so intense that it also blew up the test shack.

Sierra Space is part of a partnership with Blue Origin and others to build the Orbital Reef space station, one of four such stations with contracts with NASA. Sierra Space is building the station’s modules, while Boeing is providing the Starliner capsule for transportation. Blue Origin is supposed be providing larger modules and the New Glenn rocket for transportation, but the development of both continues to lag.

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NASA again approves design concept for Orbital Reef commercial space station

10:53 am

Proposed Orbital Reef space station

Capitalism in space: Sierra Space announced today that NASA has completed, apparently for the second time, the design review for the Orbital Reef space station that the company wants to build in partnership with Blue Origin and others, thus allowing the actual design of the station to begin.

This press release announcement, on August 22, 2022, is a bit puzzling, as Sierra Space made almost the exact same announcement in April 2022. What, did NASA have to do this twice? Did issues come up after the first approval? Was the agency reviewing different things?

Regardless, NASA as usual is slowing things down considerably. Sierra Space and Blue Origin, the primary partners in this private space station project, first announced it in October 2021. It took the government almost a year to simply approve the basic concept so that the design phase could finally begin. At this pace it will be 2090 before the station is launched.

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Sierra Space developing crewed version of Dream Chaser; will train astronauts

9:24 am

Capitalism in space: In a press release mostly focused on touting the company’s new project to establish a training center for astronauts, Sierra Space dropped this bigger story:

A crewed variant of the Dream Chaser spaceplane is currently in development and will be operational in 2026, having successfully completed its System Requirements Review (SRR) earlier this month. Orbital Reef will be on orbit and operational in 2027.

Though it was always expected that the company would upgrade the cargo version of Dream Chaser it is presently building, until now it had been made no announcement to that effect. Moreover, until now Sierra Space has functioned much like the old big space companies, doing nothing without a contract from NASA. This effort to build a manned version of Dream Chaser is apparently occurring without any such contract. All Sierra has right now is a contract to launch cargo to ISS.

The astronaut training center fits in nicely with this new manned Dream Chaser, which also fits in nicely with Sierra Space’s partnership to build the commercial space station Orbital Reef.

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Commercial Orbital Reef space station passes NASA’s design review

9:30 am

Proposed Orbital Reef space station

Capitalism in space: A proposed commercial space station dubbed Orbital Reef and being built by a partnership led by Sierra Space and Blue Origin has passed its NASA’s design review, allowing for construction to now begin.

The review, conducted as part of a $130 million development contract from NASA, found no issues with the station’s design.

This commercial partnership also includes Boeing, Redwire, Mitsubishi, Genesis Engineering, and Arizona State University, and plans its launch before 2030 when ISS will be retired. This quote from the article I think is important:

“We’re going as fast as we can,” Steve Lindsey, chief strategy officer at Sierra Space, said during a panel at the Goddard Memorial Symposium March 25. “We don’t want to have a gap like we did with crew back in the last decade.”

Three other private space stations are also under construction or being planned, all hoping to be operational prior to ’30. If even two of these launch, the 2030s will be very exciting indeed.

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Sierra Space signs Mitsubishi as partner in private Orbital Reef space station project

8:57 am

Capitalism in space: Sierra Space has now partnered with Japan’s Mitsubishi for developing technology to be used on the private commercial Orbital Reef space station project.

The companies did not elaborate on the technologies they will consider for Orbital Reef under the agreement. MHI does have extensive experience in International Space Station operations as the manufacturer of the Kibo laboratory module, which was installed on the station in 2008. The company also built the HTV cargo spacecraft and H-2 launch vehicle that launched those spacecraft to the station.

…Sierra Space’s role in Orbital Reef includes providing inflatable modules called the Large Integrated Flexible Environment (LIFE) Habitat. The company’s Dream Chaser vehicle under development will transport cargo and crew to and from the station.

A consortium led by Blue Origin announced Orbital Reef last October. In addition to Blue Origin and Sierra Space, Boeing will provide a science module, CST-100 Starliner commercial crew vehicle and support for station operations, while Redwire Space will handle microgravity research and manufacturing, payload operations and deployable structures.

This deal suggests that the project wants more experience in its stable. Also, by partnering with Mitsubishi, it likely garners political support in Japan.

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NASA awards contracts to three private space station projects

4:48 pm

Capitalism in space: NASA today announced development contract awards to three different private space station projects.

  • Nanoracks Starlab concept won $160 million. Partners include Voyager Space and Lockheed Martin.
  • Blue Origin’s Orbital Reef project was awarded $130 million, partnering with Sierra Space, Boeing, and Redwire.
  • Northrop Grumman won $125.6 million on a concept based on upgrades to its Cygnus freighter.

All three contracts are Space Act agreements, designed by NASA to jumpstart the companies and their design efforts. All three are in addition to the effort by Axiom to build its own ISS modules that will eventually detach to form its own independent station.

That’s four private American space stations now in the works. All are aiming to launch before this decade is out.

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Sierra Space raises $1.4 billion in investment capital

9:28 am

Capitalism in space: Sierra Space, the space subsidiary of Sierra Nevada, has raised $1.4 billion in investment capital in a recent round of fund-raising.

The company will use the funds to support development of Dream Chaser, the lifting-body vehicle it is building for to transport cargo for the International Space Station starting in late 2022. The company originally developed Dream Chaser to carry people as a competitor in NASA’s commercial crew program, and company executives have frequently stated they still plan to develop a crewed version at a later date.

The funds will also support development of its Large Integrated Flexible Environment (LIFE) inflatable module. Both LIFE and Dream Chaser are part of Orbital Reef, the commercial space station concept announced Oct. 25 by a team that includes Sierra Space along with Blue Origin, Boeing and Redwire.

It appears that the investment community likes the Orbital Reef commercial space station concept, and especially likes Sierra Space’s part in it. This influx of cash also suggests that the investors got a good look at the status of Dream Chaser, and were satisfied its development was proceeding as planned.

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Sierra Space teams up with Blue Origin to build its Life space station

10:45 am

Proposed Orbital Reef space station

Capitalism in space: Sierra Space and Blue Origin today announced [pdf] that they are forming a consortium of space companies to build a space station they dub Orbital Reef. From the press release:

The Orbital Reef team of experts brings proven capabilities and new visions to provide key elements and services, including unique experience from building and operating the International Space Station:

  • Blue Origin – Utility systems, large-diameter core modules, and reusable heavy-lift New Glenn launch system.
  • Sierra Space – Large Integrated Flexible Environment (LIFE) module, node module, and runway-landing Dream Chaser spaceplane for crew and cargo transportation, capable of landing on runways worldwide.
  • Boeing – Science module, station operations, maintenance engineering, and Starliner crew spacecraft.
  • Redwire Space – Microgravity research, development, and manufacturing; payload operations and deployable structures.
  • Genesis Engineering Solutions – Single Person Spacecraft for routine operations and tourist excursions.
  • Arizona State University – Leads a global consortium of universities providing research advisory services and public outreach.

I suspect that this deal is actually telling us that Jeff Bezos is spreading some of his Blue Origin money to help finance Sierra Space’s work. The deal also appears to be an effort to generate work for Blue Origin’s not-yet-launched New Glenn rocket and Boeing’s not-yet launched Starliner capsule.

The release says nothing about target dates, but the overview [pdf] on the Orbital Reef website says they are aiming for the second half of this decade.

While the success of such a project can only increase the competition and lower the cost to orbit, thus making the settlement of space more likely, this announcement reeks of the same kind of high-minded promises that came with Blue Origin’s Blue Moon lunar lander: Big plans by the best and most established space companies, with little firm commitment by these companies to actually build anything.

Compared to the Blue Moon lunar lander project, however, this project has one very significant difference that could make it real. Orbital Reef is not being touted in order to win a government contract. It is being touted as a commercial station for private customers. Such a project will require these companies to either invest their own money, or obtain outside investment capital, to build it. To make money they can’t sit and wait for their customers to pay for it, since customers never do that (except the government). They need to first build it.

Meanwhile, the BE-4 engine is not yet flight worthy, so that Blue Origin’s New Glenn rocket remains no closer to launch, even though it is now approaching two years behind schedule.

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