LOUISVILLE, Colo. – Nov. 13, 2023 – Sierra Space, a leading pureplay commercial space company building the first end-to-end business and technology platform in space, announced today that it is on the brink of a historic moment as the company prepares for its biggest-ever “burst test” of Sierra Space’s inflatable, expandable space station technology.

This groundbreaking endeavor marks a critical step in Sierra Space’s co-development of Orbital Reef with Blue Origin, as the company plans to stress test – for the first time in history – a full-scale version of its LIFE™ habitat structure and bring the unit to failure under pressure. LIFE is constructed of high-strength “softgoods” materials, which are sewn and woven fabrics – primarily Vectran – that become rigid structures when pressurized on orbit. To date, Sierra Space has conducted five stress tests on subscale test articles; this next one will be 18x larger – nearly 300 m³ of pressurized volume.

Scheduled for December 2023 at the NASA Marshall Space Flight Center in Huntsville, Ala., the Ultimate Burst Pressure (UBP) test is expected to provide Sierra Space and the Orbital Reef program team with critical data in support of NASA’s softgoods certification guidelines. The over-pressurization to failure during the test will not only demonstrate the habitat’s capabilities but also open avenues for structural enhancements.

Sierra Space’s expandable space station module technology is highly scalable and flexible to all existing and planned launch vehicle fairing sizes. The softgoods structures launch packed inside conventional rocket fairings – 5m, 7m, 9m and beyond – inflating to capacity on orbit. Low-volume launches become high-volume space stations. The module volume will always be the square of its expansion diameter. For example, with a 2.5x expandable configuration, the volume would be 6.25x of a rocket fairing.

“Sierra Space’s inflatable space station module technology offers the absolute largest in-space pressured volume, the best unit economics per on-orbit volume and lowest launch and total operating costs,” said Sierra Space CEO Tom Vice. “Having the best unit economics positions Sierra Space as the category leader in microgravity research and product development – providing customers with the most attractive return on their investment.”

Key Dimensions:

• Full scale LIFE habitat with a height of 20.5 feet (Total height with ground support equipment: 29.5 feet)
• Diameter: 27 feet
• Volume: 10,000 cubic feet (283.17 m3)

Current Progress:

All components and ground support equipment are in the integration phase at NASA Marshall Space Flight Center Upcoming Steps: Softgoods integration into the test stand will be followed by transportation, utilizing the legendary NASA KAMAG transporter tractor, to the historic testing location adjacent to the flame trench of the Saturn 1/1B test stand — where NASA tested rockets for the Apollo program. Setup and calibration of sensors and cameras, alongside operational run-throughs, will prepare for the full-scale UBP test in December 2023.

Objectives and Lessons Learned:

The recent successes of subscale burst tests have emboldened Sierra Space to undertake the full-scale burst test with confidence. Sierra Space aims to further refine its technical approach to safety factors and structural integrity through this test. Insights from previous tests contribute to technical maturation in support of higher-fidelity manufacturing processes.

Core Materials and Blanking Plates:

• The restraint layer for LIFE is constructed of high-strength “softgoods” materials, which are sewn and woven fabrics – primarily Vectran – that become rigid structures when pressurized
• Under normal operating pressure, the Vectran softgoods materials become 5x stronger than steel, exceeding station lifetime performance safety factors
• The restraint layer is complemented by a bladder allowing controlled inflation and pressurization to ultimate burst pressure test failure
• Two metallic blanking plates are strategically inserted into the restraint layer, designed for seamless integration into the structural shell with minimal performance degradation or knockdown; blanking plates are metal placeholders for integrating windows, airlocks, robotic arms and other features, into the softgoods layer

About Sierra Space

Sierra Space is a leading, pureplay commercial space company at the forefront of innovation and the commercialization of space in the Orbital Age™, building an end-to-end business and technology platform in space to benefit life on Earth. With more than 30 years and 500 missions of space flight heritage, the company is enabling the future of space transportation with Dream Chaser®, the world’s only commercial spaceplane, and is bringing LIFE™ (Large Integrated Flexible Environment) to low-Earth orbit with its modular, three-story commercial habitation and science platform. Both Dream Chaser and LIFE are central components to Orbital Reef, a mixed-use business park in LEO being developed by principal partners Sierra Space and Blue Origin, which is expected to be operational by the end of the decade. Sierra Space also builds and delivers a host of systems and subsystems across solar power, mechanics and motion control, environmental control, life support, propulsion and thermal control, offering myriad space-as-a-service solutions for the new space economy.

Source: Sierra Space

Nov. 2, 2023 – Sierra Space, a leading pureplay commercial space company building the first end-to-end business and technology platform in space, today proudly revealed the fruit of years of passionate determination, countless breakthrough innovations and relentless commitment, the remarkable Dream Chaser spaceplane. The first vehicle is complete and will ship to NASA’s Neil A. Armstrong Test Facility in Ohio for environmental testing in coming weeks.

Dream Chaser is a leap forward in space technology, heralded as the world’s sole commercial runway-capable spaceplane. Supported by a substantial contract from NASA to resupply the International Space Station, Dream Chaser is poised to lead the way in democratizing access to space, forging a path towards shared space exploration and international cooperation.

“Today we have arrived at a profound milestone in both our company’s journey and our industry’s future – one that has been years in the making and is shaped by audacious dreaming and tenacious doing,” said Sierra Space CEO Tom Vice.

“I am reminded of a comment made by Steve Jobs that every once in a while, a revolutionary product comes along that changes everything. I think Dream Chaser is that product. This breakthrough shifts paradigms and redefines space travel. The Dream Chaser is not just a product; it’s a testament to human spirit, determination and the relentless pursuit of what lies beyond.”

Sierra Space team members gathered to celebrate this milestone moment on October 30th, at the company’s Louisville, CO, production facility.

Unlocking Opportunities for Space Access

The versatile Dream Chaser spaceplane fleet is meticulously designed to facilitate the transportation of cargo and, in the future, crew to low-Earth orbit (LEO). This multi-mission platform offers customization options to cater to the needs of both domestic and international customers, further enhancing its role in global space operations. Under NASA’s Commercial Resupply Services 2 (CRS-2) contract, Dream Chaser has been selected to provide essential cargo delivery, return, and disposal services for the International Space Station.

Unparalleled Design and Precision

At the heart of Dream Chaser is an unparalleled design, meticulously crafted with precision. Every curve and contour of this remarkable vehicle is engineered for excellence, seamlessly merging engineering with a beautiful design, and enabling the seamless integration of space travel and hypersonic atmospheric speeds.

Pinnacle of Technological Advancement

Harnessing cutting-edge technology, Dream Chaser showcases its mettle by safely withstanding temperatures exceeding 3,000 degrees during re-entry, all while being cool to the touch mere minutes after landing. The incorporation of the most advanced autonomous flight system, ensuring a minimum 15-mission lifespan, marks a monumental leap forward in space transportation.

Safety as a Cornerstone

Safety remains at the core of the Dream Chaser’s mission. Advanced safety mechanisms fortify the spaceplane, guaranteeing the integrity of the cargo – including sensitive scientific payloads – and the well-being of all those aboard the International Space Station who will interact with the new vehicle.

A Commitment to Sustainability

While we soar towards the heavens in pursuit of dreams, we remain resolutely anchored to our commitment to the planet. Dream Chaser is designed with sustainability as a foundational principle, working toward a better future for all. Years of dedication have resulted in the creation of a revolutionary new propulsion and oxidizer-fuel system, a testament to our pledge to a more eco-friendly and responsible approach to space travel.

Tenacity’s Historic Mission

The inaugural Dream Chaser spaceplane, “Tenacity,” is poised to embark on its initial seven cargo missions to and from the International Space Station, carrying essential supplies such as food, water and scientific experiments. One of Dream Chaser’s groundbreaking features is its capability to safely return critical cargo to Earth at fewer than 1.5g’s, ensuring the preservation of invaluable payloads. This innovative spaceplane offers unparalleled flexibility and can land at any compatible commercial runway worldwide, just like a narrow body commercial airliner.

Setting New Standards for Reusability and Adaptability

Dream Chaser’s high reusability and adaptability set it apart, making it an optimal choice for a wide range of applications while ensuring rapid turnaround times to meet various LEO requirements. The launch for this extraordinary journey is schedule to occur from NASA’s Kennedy Space Center. Sierra Space’s launch provider, United Launch Alliance (ULA), will carry Dream Chaser into orbit on the second Vulcan Centaur rocket. Tenacity’s maiden resupply mission will culminate with the vehicle’s return, landing at the historic NASA Space Shuttle Landing Facility.

As we unveil the Dream Chaser, we invite you to join us on this extraordinary journey. Together, we embark on a new chapter in space transportation, redefining what’s possible and shaping the future of human exploration. Sierra Space’s Dream Chaser spaceplane symbolizes the dawn of a new era in space commercialization – The Orbital Age™, marked by heightened efficiency, extensive reusability and boundless opportunities. As “Tenacity” embarks on its maiden mission, it sets the stage for a brighter future of space transportation and cooperation, bringing humanity’s dreams of space exploration one step closer to reality.

Source: Sierra Space

LOUISVILLE, Colo. – July 26, 2023 – Sierra Space, a leading commercial space company building the first end-to-end business and technology platform in space, today announced it has been awarded a $22,605,083 firm-fixed-price contract for maturation of their Advanced Upper Stage Engine (VR35K-A). The company successfully completed a 100% hot fire test campaign of this new VORTEX® engine this spring, marking a significant maturation milestone for the upper-stage engine that Sierra Space is developing in conjunction with the Air Force Research Laboratory.

According to the U.S. Department of Defense, this contract provides for “leveraging the test data from the first Phase III Small Business Innovation Research component and integrated breadboard engine test to develop flight-weight engine component designs.” The Air Force Test Center at Edwards Air Force Base in California awarded the sole-source acquisition contract.

The VR35K-A is a liquid oxygen (LOX)/liquid hydrogen (LH2) engine that produces 35,000 lbf of thrust. The engine achieved high thrust efficiency during recent testing at the company’s propulsion test facility outside of Baraboo, Wisc. VORTEX technology will serve a critical industry need for engines that can support in-space propulsion for spacecraft orbital maneuvering and extraterrestrial landers.

“Compared with other upper-stage engines currently on the market, the VR35K-A provides more thrust and higher performance in a smaller package,” said Rusty Thomas, Sierra Space’s Chief Technology Officer and Vice President and General Manager for the Space Applications business sector. “Think of it like gas mileage – how much thrust can you get out of a given amount of propellant? Once complete, the VR35K-A will allow our launch vehicle teammates and partners to deliver up to 30% more payload mass to orbit. It will drive technology across all propulsion products at Sierra Space – from our applications and destinations sectors to space transportation with our Dream Chaser® spaceplane.”

The VR35K-A is rooted in Sierra Space’s patented VORTEX engine design technology, which promotes efficient, stable combustion while also cooling the combustion chamber. Key system attributes providing high performance and low recurring cost include innovative single-shaft turbopump assembly for simplified operation and mechanically-coupled mixture ratio control, fuel-rich staged combustion cycle to drive high chamber pressure and subsequent compactness, vortex main propellant injector to increase overall cooling capacity and heavy use of additive manufacturing to reduce production costs and schedule of complex parts.

In August 2022, Sierra Space announced the VR35K-A had passed its Critical Design Review, which allowed the company to advance into the hot fire testing campaign. Next, Sierra Space will continue to advance the VR35K-A engine by completing build of the flight-weight prototype engine to demonstrate capability and performance, and ultimately move into full engine qualification testing.

About Sierra Space

Sierra Space (www.sierraspace.com) is a leading, pure play commercial space company at the forefront of innovation and the commercialization of space in the Orbital Age™, building an end-to-end business and technology platform in space to benefit life on Earth. With more than 30 years and 500 missions of space flight heritage, the company is enabling the future of space transportation with Dream Chaser®, the world’s only commercial spaceplane, and is bringing LIFE™ (Large Integrated Flexible Environment) to low-Earth orbit with its modular, three-story commercial habitation and science platform. Both Dream Chaser and LIFE are central components to Orbital Reef, a mixed-use business park in LEO being developed by principal partners Sierra Space and Blue Origin, which is expected to be operational by the end of the decade. Sierra Space also builds and delivers a host of systems and subsystems across solar power, mechanics and motion control, environmental control, life support, propulsion and thermal control, offering myriad space-as-a-service solutions for the new space economy.

Source: Sierra Space

LOUISVILLE, Colo. – May 31, 2023 – Sierra Space, a leading, pureplay commercial space company building the first end-to-end business and technology platform in space, is thrilled to announce the successful power up of its revolutionary Dream Chaser® spaceplane. Dream Chaser represents a groundbreaking leap in space transportation technology, designed to provide reliable and cost-effective access to space for a wide range of applications. With its unique lifting body design, the spaceplane combines the flexibility of an aircraft with the capabilities of a spacecraft, revolutionizing space travel.

The power-up of Dream Chaser signifies the activation of its integrated systems, showcasing the culmination of years of rigorous engineering, design, and testing. 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.

“This is a milestone that points to the future and is a key moment in a long journey for Dream Chaser.” said Tom Vice, CEO of Sierra Space. “With this significant achievement, our Dream Chaser spaceplane is poised to redefine commercial space travel, opening up new possibilities for scientific research, technological advancements, and economic opportunities in space.”

The successful test was a key moment for the progress of space technology after years of design and development across Sierra Space, enabled by the accomplishments of many teams from system level design to final assembly and test.

Dream Chaser is a reusable, fully autonomous, orbital spaceplane designed to transport cargo to low-Earth orbit (LEO) destinations such as the International Space Station (ISS) and land at conventional runways. Measuring about one-quarter the size of the Space Shuttle, it features autonomous launch, flight, and landing capabilities with a smooth 1.5 low-G re-entry on compatible commercial runways worldwide.

About Sierra Space

Sierra Space is a leading, pureplay commercial space company at the forefront of innovation and the commercialization of space in the Orbital Age™, building an end-to-end business and technology platform in space to benefit life on Earth. With more than 30 years and 500 missions of space flight heritage, the company is enabling the future of space transportation with Dream Chaser® the world’s only commercial spaceplane and is bringing LIFE™ (Large Integrated Flexible Environment) to low-Earth orbit with its modular, three-story commercial habitation and science platform. Both Dream Chaser and LIFE are central components to Orbital Reef, a mixed-use business park in LEO being developed by principal partners Sierra Space and Blue Origin, which is expected to be operational by the end of the decade. Sierra Space also builds and delivers a host of systems and subsystems across solar power, mechanics and motion control, environmental control, life support, propulsion and thermal control, offering myriad space-as-a-service solutions for the new space economy.

Source: Sierra Space