Tag: Sierra Space

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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New thermal protection system developed by Sierra Space

10:27 am

Sierra Space yesterday announced that it has developed in partnership with Department of Energy’s Oak Ridge National Laboratory in Tennessee a new thermal protection system (TPS] that it expects will give its Dream Chaser mini-shuttles a heat shield that can be reused frequently and fast.

The TPS tiles are made of a proprietary composite material that’s as strong as carbon fiber but with the added high-temperature stability of ceramic materials. The composite tiles have low-density thermal protection properties that are vital for insulative protection and stable flight dynamics. Atmospheric re-entry exposes spacecraft to speeds of more than Mach 17 (About 13,000 mph or 21,000 kph) with temperatures reaching higher than 3,100 degrees Fahrenheit (1,704 degrees Celsius).

These new tiles are based on the shuttle tiles, but apparently use carbon fibers to strengthen them so they are more robust and require less replacement. The shuttle tiles were much too fragile, requiring significant replacement after each launch. That fragility also caused the destruction of Columbia on its return to Earth in 2003, because the tiles were damaged badly when hit by foam coming off the shuttle during launch.

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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 wins NASA contract to develop trash compactor for use in space

9:47 am

Sierra Space yesterday announced that it has won a NASA contract to develop trash compactor for use in space and test it on ISS by 2026.

The system’s goals will not only be to reduce the volume of waste, but to recover all the water contained within it.

Current primary waste systems in space cannot reclaim water or effectively reduce the volume of trash in a manner necessary for long-term space travel. The TCPS [Sierra’s compactor] is being developed to recover nearly all the water from the trash for additional use. This capability may be vital not only for deep space exploration but also for commercial orbital facilities or extraterrestrial bases. As a stand-alone system, TCPS only requires access to power, data, and air-cooling interfaces and it provides a simple user interface to facilitate crew interactions.

The key to this development is that it isn’t being developed by NASA solely for ISS. Sierra will own the product, and design it to be used on any in-space operation, from space stations to lunar bases.

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Sierra Space wins Air Force contract to develop orbital cargo delivery system

9:49 am

The Air Force has now awarded Sierra Space a contract to develop its proposed “Space Ghost” satellite spacecraft, designed to be launched into a stand-by orbit carrying needed cargo, where it can upon command deliver that cargo within 90 minutes anywhere on Earth.

Sierra Space won a contract of undisclosed value as part of the AFRL’s Rocket Experimentation for Global Agile Logistics (REGAL) program. The Air Force is exploring the potential of space vehicles to rapidly transport critical supplies from orbital warehouses back to Earth. This could include reusable reentry vehicles capable of delivering payloads from prepositioned stocks in orbit.

Sierra Space, based in Louisville, Colorado, said its defense technology team designed the Ghost system to be capable of remaining in orbit for up to five years, storing and delivering essential supplies on-demand. Once fully developed, the spacecraft could be used for missions such as delivering rescue kits for downed pilots, medical supplies for disaster relief or logistical support for military operations.

The company began doing drop tests of a Space Ghost prototype heat shield in March, and apparently the data satisfied the Air Force enough to issue this development contract. Whether such a system however makes sense remains unknown. To be able to deliver cargo anywhere on Earth will require putting up a large constellation of Space Ghost satellites, in many different orbits. Moreover, it is unclear how much cargo each satellite would carry.

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Sierra Space successfully tests equipment for extracting oxygen from the lunar soil

9:57 am

In a press release this week Sierra Space revealed that it has successfully tested an extraction system that can gather up the abrasive lunar regolith and then heat it to high temperatures in order to extract and use the oxygen contained in that soil.

Temperatures in which the Sierra Space Carbothermal Oxygen Production Reactor were tested ranged from minus 45 degrees Celsius to 1,800 degrees Celsius. In addition to the challenges of functioning from sub-zero to hotter-than-lava temperatures, the hardware was required to move the simulated lunar regolith – a very abrasive and jagged material because it does not have the weathering processes found on Earth – through its system. The potentially damaging particles were handled effectively by the hardware and gasses were successfully sealed inside the reactor, thanks to Sierra Space’s use of a patent-pending valve design that previously demonstrated functionality to greater than 10,000 cycles.

The tests confirmed that Sierra Space’s system can successfully handle regolith that would be delivered from a lunar rover or robotic arm and automatically bring it into the reaction chamber, perform the carbothermal reduction reaction process to extract the oxygen from the minerals in the regolith, and remove the processed regolith from the system so the operation can be repeated.

This research is similar to the extraction system the Chinese are developing, though it appears Sierra’s system appears considerably closer to a finished product, as it is already being tested.

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Sierra Space completes acoustic testing of Shooting Star cargo module that will fly on first Dream Chaser launch

9:45 am

Sierra Space today announced that it has successfully completed acoustic testing of the Shooting Star cargo module that will fly on first ISS mission of its Tenacity Dream Chaser mini-shuttle.

During the Direct Field Acoustic Test (DFAN), the test team placed stacks of purpose-built loudspeakers – each one a highly-engineered acoustic device – in 21-ft-tall columns surrounding the spacecraft. Their goal was to test whether the structural elements of Shooting Star could withstand the acoustic environment of a launch on a Vulcan Centaur rocket. Over a four-day period, test engineers blasted the spacecraft with a controlled sound field that was 10,000x higher intensity than the volume of a typical rock concert, recreating the sonic intensity of a launch. Shooting Star withstood acoustic levels greater than 140 dB for several minutes at a time, proving its flight worthiness.

The press release however made no mention as to when the launch will actually take place. Sierra first got the contract to build Dream Chaser in 2016, and was supposed to make its first flight in 2020. That launch has been repeatedly delayed, and is now four years behind schedule. Supposedly it was to take place this year on the second launch of ULA’s Vulcan rocket in the spring of 2024, but was removed from that launch because of delays in preparing Tenacity for launch.

As of today, no new launch date has been announced, and though Sierra says Tenacity will be ready for launch by the end of this year, don’t expect it to happen before 2025.

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Sierra Space in negotiations to buy ULA

10:26 pm

According to the Reuters news agency, Sierra Space is negotiating with the joint owners of ULA, Boeing and Lockheed Martin, to buy the rocket company.

The sources, which are all anonymous, said the sale price is in the range of $2 to $3 billion. Those same sources said no deal has yet been worked out, and might not happen at all.

For Sierra, the deal would give it its own launch vehicle, Vulcan, for placing its Dream Chaser mini-shuttles into orbit. It would also give it a profit stream from the many military and commercial launch contracts already on ULA’s manifest. The combined cababilities of ULA and Sierra will create a formidable new player in the aerospace launch market.

For Boeing, it would provide it some much needed cash that it will be able to use to both restructure and revitalize its presently questionable operations.

It is unclear what Lockheed Martin will gain from the sale, other than the cash and the removal of this Frankenstein-like partnership with Boeing, which in the long run has probably not done it a lot of good.

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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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ULA replaces Sierra’s mini-shuttle with dummy payload to launch Vulcan in September

9:28 am

Because of continuing delays in preparing Sierra Space’s Tenacity Dream Chaser mini-shuttle for launch, ULA has been forced to remove it from the second launch of Vulcan in order to proceed with the launch in September as planned.

ULA needs to launch Vulcan for the second time and as soon as possible in order to get approval from the Pentagon to do military launches. The delays in getting Tenacity ready for launch has already impacted that schedule, as ULA had originally hoped to launch Vulcan on its second flight — with Tenacity as the payload — several months ago. Further delays beyond September would seriously damage not only ULA’s bottom line, but the military’s own needs. It is all for these reasons that ULA has now set up a new review team to force this schedule forward, likely under pressure from the Pentagon.

Sierra Space meanwhile says that Tenacity is still on track to be ready to launch before the end of the year, but it is unclear what rocket will carry it. ULA will likely offer another Vulcan rocket for the purpose, but to do so it will probably have to delay some other payload, and it is certain it will not do that to any upcoming military launches. Based on the announced launch schedule, it does not look like this launch can occur on a ULA rocket in 2024. ULA says it hopes to launch at least 20 times in 2025, so one of those launches will likely carry Tenacity.

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Sierra Space’s Tenacity mini-shuttle arrives at the Cape

9:30 am

Capitalism in space: Sierra Space’s Tenacity Dream Chaser mini-shuttle has finally arrived at the Kennedy Space Center in Florida for its final testing and assembly onto ULA’s Vulcan rocket.

Upon arrival at Kennedy, teams moved Dream Chaser Tenacity to the high bay inside the Space Systems Processing Facility, where it will undergo final testing and prelaunch processing ahead of its launch scheduled for later this year.

…The remaining pre-flight activities at Kennedy include acoustic and electromagnetic interference and compatibility testing, completion of work on the spaceplane’s thermal protection system, and final payload integration.

If all goes right, Tenacity’s first mission will last 45 days, delivery about 7,800 pounds of cargo to ISS, and prove out the reusable mini-shuttle for up to seven more flights to ISS.

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Sierra Space confirms its Tenacity spacecraft successfully completed vibration testing

9:16 am

Sierra Space yesterday confirmed that its first Dream Chaser reusable mini-shuttle Tenacity, being readied for a hoped-for April launch, successfully completed vibration testing last month.

Key accomplishments in this first critical phase of pre-flight testing included: the completion of Sine Vibration Testing (in all three axes or directions), a Separation Shock Test that simulates the separation of the Dream Chaser from Shooting Star and a test that involved deploying the spaceplane’s wings. These tests evaluated Dream Chaser’s performance under the stresses of launch, operation in orbit and ability to communicate with the International Space Station (ISS).

What I find revealing about the press release at the link is that it really adds nothing from a NASA press release from a month ago. Then NASA said that Tenacity was about to move to a vacuum chamber for environmental testing. According to this new press release, that move has still not occurred and the environmental test still must begin.

That engineers didn’t move Tenacity to environmental testing while they were reviewing the vibration test data suggests there was something in that test data that prevented it. It appears that unstated issue is resolved, but it caused a pause in testing.

As a result, it appears that an April launch is unlikely delayed by a month or more, assuming my attempt to read between the lines is correct.

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Vibration testing of Sierra Space’s Tenacity mini-shuttle completed

9:01 am

NASA engineers have now completed vibration testing of Sierra Space’s Tenacity mini-shuttle, set to launch on a Vulcan rocket later this year.

Reading between the blather in the NASA press release at the link, it appears that testing was successful, proving that the Dream Chaser spacecraft can survive the vibrations of launch. This conclusion by me however remains unconfirmed. Engineers are now preparing the mini-shuttle for environmental testing.

Next up, Dream Chaser will move to a huge, in-ground vacuum chamber that will continue to simulate the space environment Dream Chaser will encounter on its mission. The spaceplane will be put through its paces, experiencing low ambient pressures, low-background temperatures, and dynamic solar heating.

Previously the launch date had been targeting April 2024, according to ULA officials. It now appears, from the vagueness of recent reports, as well as the actual testing now in progress, that the launch date has slipped. They appear to be targeting the first half of 2024, but are as yet unwilling to commit to a date.

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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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Military awards satellite contracts worth $2.5 billion to three companies

9:25 am

The Pentagon’s Space Development Agency (SDA) today announced the award of contracts to Sierra Space, Lockheed Martin, and L3Harris for the construction of 54 reconnaissance satellites, with a total value of $2.5 billion.

The 54 satellites will form part of the SDA’s Proliferated Warfighter Space Architecture, a massive missile detection and tracking constellation in low Earth orbit that’s being built and launched in “tranches.” The trio of contracts announced today is for 18 satellites each in the Tranche 2 Tracking Layer: L3Harris’s award is worth $919 million; Lockheed Martin, $890 million; and Sierra Space, $740 million.

Last week SDA had awarded Rocket Lab its own 18-satellite contract for this constellation, worth $515 million.

The contract awards signal several major changes in the Pentagon’s space strategy. First, it is farming the work out to multiple companies, two of which (Rocket Lab and Sierra Space) are new. In the past the military relied on a very limited number of companies, all well established, with most contracts going to only one vender. New companies had great difficulties getting in the door.

Second, it is building a constellation of smallsats rather than single large satellites. Smallsats are cheaper to build and replace, and are much harder military targets to hit.

Third, though it appears the military is designing these satellites, it appears it is still shifting much of the work from it to the private sector. In other words, the Pentagon is becoming a customer instead of a builder. The result will be a healthy space industry capable of doing more for itself and the military.

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NASA: The flight plan for Dream Chaser Tenacity’s first demo mission to ISS

9:30 am

NASA today provided a detailed description of the flight plan for the first demo ISS mission of Sierra Space’s first Dream Chaser reuseable mini-shuttle, dubbed Tenacity, now targeting some unspecified date in 2024.

It will carefully approach ISS, testing its maneuvering and rendezvous capibilities, and then be grabbed by the station’s robot arm to be berthed to the station.

On its first flight to the International Space Station, Dream Chaser is scheduled to deliver over 7,800 pounds of cargo. On future missions, Dream Chaser is being designed to stay attached to the station for up to 75 days and deliver as much as 11,500 pounds of cargo. Cargo can be loaded onto the spacecraft as late as 24 hours prior to launch. Dream Chaser can return over 3,500 pounds of cargo and experiment samples to Earth, while over 8,700 pounds of trash can be disposed of during reentry using its cargo module.

On this first demo flight it will remain docked for 45 days, and then land on the shuttle runway at Cape Canaveral.

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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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Sierra Space: Tenacity is complete and ready for ground testing

9:50 am

Sierra Space announced yesterday that its reuseable Tenacity cargo freighter, the first of its Dream Chaser mini-shuttles, is now complete and ready shipment to NASA’s test facilities in Ohio for ground testing.

The spacecraft hopefully will fly next year. Though this is four years behind schedule, it signals an important milestone for the company, and suggests its operational pace will pick up afterward. Though its arrival comes very late in ISS’s lifespan, the coming arrival of many private space stations, including Sierra’s own, will likely provide it many customers.

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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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Sierra Space raises another $290 million in private investment capital

2:26 pm

Sierra Space today announced that during its most recent funding round it successfully raised another $290 million in private investment capital, bringing the total capital it has raised to $1.7 billion.

The round is co-led by Japan’s largest bank, MUFG, Kanematsu Corporation, a Japanese trading company and Tokio Marine & Nichido Fire Insurance, Japan’s largest property and casualty insurance group with participation from Sierra Space’s existing investors. The companies are already participating in a JAXA (Japanese Aerospace Exploration Agency) study to explore how to conduct activities in LEO as the ISS approaches the end of service.

These Japanese partnerships act to strengthen Sierra’s already strong links to Japan, including ongoing negotiations to land its Dream Chaser reusable mini-shuttes at Oita Airport, as well as partnership deals with Kanematsu, Japan Airlines and Mitsubishi.

This successful fund-raising round suggests strongly that the company’s plans to finally have its first Dream Chaser cargo shuttle, Tenacity, ready to fly in December might actually happen. Or at least, that plan acted to convince these investors to pony up some cash.

Hat tip to Jay, BtB’s stringer.

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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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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 powers up its Dream Chaser mini-shuttle for the first time

9:09 am

Sierra Space yesterday announced that it has successfully run electricity for the first time through its first Dream Chaser mini-shuttle, dubbed Tenacity.

The press release is remarkably lacking in detailed information, or graphics. This quote is really the only hard facts mentioned:

Sierra Space simulated the power that will be generated from Dream Chaser’s solar arrays once on orbit. Test engineers plugged that power into Dream Chaser and began turning on systems. Sierra Space exercised flight computers, base processors and low-voltage distribution units.

Tenacity has been under construction since 2016, when the company won its NASA contract to build it. That’s seven years to build a single spacecraft, and yet all they have done so far is feed electricity through it for the first time. In that time period SpaceX not only built multiple prototypes of Starship and Superheavy, it has flown multiple test flights.

Is money an issue? The actual contract amount NASA gave Sierra Space to build Tenacity has never been published, though NASA has said the total awarded for all the cargo missions to be flown by SpaceX, Northrop Grumman, and Sierra Space equaled $14 billion. Since these fixed price contracts also require the companies also commit some of their own funds, or obtain outside financing, it is possible that Sierra Space has had money issues slowing development.

Regardless, Dream Chaser was first supposed to fly in 2020. It is now three years late, with no clear indication that a launch will come anytime soon. In many way, Sierra Space is beginning to remind me of Blue Origin, endlessly issuing promises but never delivering.

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Launch of Sierra Space’s Dream Chaser now scheduled for six month window opening in August

9:47 am

After years of delays, Sierra Space’s first Dream Chaser reusable mini-shuttle, dubbed Tenacity, is now scheduled for launch during the six month mission to ISS of a crew scheduled for launch in August.

Dream Chaser’s first flight on a United Launch Alliance Atlas V rocket is expected while Crew-7 is aboard and two of those crew members, NASA’s Jasmin Moghbeli and JAXA’s Satoshi Furukawa, recently trained on it. JAXA and NASA formally announced Furukawa’s assignment to Crew-7 today. Furukawa, Moghbeli, ESA’s Andreas Mogensen and a Russian cosmonaut whose assignment has not been officially announced yet, are expected to launch in mid-August for a 6-month stay on the ISS.

The exact launch date within that mission has not yet been determined. It will largely depend scheduling, fitting it in with other launches to the station, assuming Tenacity’s construction is finished in time. That construction began in 2015, and has taken three to four years longer than first announced.

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ILC Dover to provide spacesuits and “softgoods” for Sierra Space’s LIFE space station

9:08 am

Sierra Space yesterday announced that it has signed a partnership deal with ILC Dover for it to provide spacesuits and other “softgoods” for Sierra Space’s LIFE space station, including helping to build the station’s inflatable modules.

ILC Dover will be an exclusive partner with Sierra Space for softgoods used to support inflatable space habitat systems for low-Earth orbit (LEO), lunar and Mars transport and surface habitation, and use cases even farther into deep space.

The two companies have already been working together on the development and testing of Sierra Space’s first prototype inflatable modules.

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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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September 13, 2022 Quick space links

4:48 pm

Courtesy of stringer Jay.

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September 6, 2022 Quick space links

5:16 pm

Courtesy of Jay, BtB’s intrepid stringer.

  • Sierra Space: Mission: Tenacity Part 1

    • This video is just an empty-of-content commercial for Sierra Space, filled with feel-good “woke” blather but little real information about the actual status of this long overdue spacecraft. It is worth watching however because it reveals this emptiness. Reminds me of the many similar videos from Blue Origin and NASA over the years, filled with big promises but little actual achievement.

  • How does Starlink Satellite Internet Work?

    • This video, almost 30 minutes long, is definitely worth watching if you have any interest in signing up for Starlink, or just have an interest in the coming low orbit satellite constellation boom.

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August 31, 2022 Quick space links

3:47 pm

Thanks to BtB’s stringer Jay.

That’s nice, but years have passed and the first Dream Chaser cargo spacecraft, Tenacity, has still not flown. It is well past time for this company to finally get off the ground.

This also be the first spacewalk using the airlock on the space station’s new Wentian module.

It appears to be built by the pseudo-company Orienspace.

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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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