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Sierra Space’s Dream Chaser New Station Resupply Spacecraft for NASA


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NASA and Sierra Space are making progress on the first flight of the company’s Dream Chaser spacecraft to the International Space Station. The uncrewed cargo spaceplane is planned to launch its demonstration mission in 2024 to the orbital complex as part of NASA’s commercial resupply services.
NASA and Sierra Space are making progress on the first flight of the company’s Dream Chaser spacecraft to the International Space Station. The uncrewed cargo spaceplane is planned to launch its demonstration mission in 2024 to the orbital complex as part of NASA’s commercial resupply services.
Sierra Space

NASA and Sierra Space are making progress on the first flight of the company’s Dream Chaser spacecraft to the International Space Station. The uncrewed cargo spaceplane is planned to launch its demonstration mission in 2024 to the orbital complex as part of NASA’s commercial resupply services.

Dream Chaser and Shooting Star

The Dream Chaser cargo system, manufactured by Sierra Space in Louisville, Colorado, consists of two major elements: the Dream Chaser spacecraft and the Shooting Star cargo module. As a lifting body spacecraft, Dream Chaser is designed to be reused up to 15 times, and is modified from the HL-20 spacecraft developed at NASA’s Langley Research Center in Hampton, Virginia.

The spaceplane’s cargo module companion, Shooting Star, is designed to support delivery and disposal of pressurized and unpressurized cargo to and from the space station. The cargo module can be used only once and is disposed of prior to re-entry.

The Dream Chaser system will launch with its wings folded inside a five-meter fairing aboard a ULA (United Launch Alliance) Vulcan Centaur rocket from Space Launch Complex 41 at Cape Canaveral Space Force Station in Florida. The fairing panels will protect the spacecraft during ascent but are jettisoned once in orbit. Solar arrays mounted on the cargo module and wings of Dream Chaser are deployed during its autonomous rendezvous to the space station. In the event of a scrub, Dream Chaser is designed to be ready for launch in as little as 24 hours.

Mission Overview

During its first flight, Sierra Space will conduct in-orbit demonstrations to certify Dream Chaser for future missions. Teams at NASA’s Kennedy Space Center in Florida, NASA’s Johnson Space Center in Houston, and the Dream Chaser Mission Control Center in Louisville, Colorado, will monitor the flight. Sierra Space flight controllers will control the Dream Chaser spacecraft on the launch pad until the spacecraft is handed over to the Sierra Space ground operations team at NASA Kennedy following landing.

Far-field demonstrations will be conducted outside the vicinity of the space station before the spacecraft enters the approach ellipsoid, a 2.5-by-1.25-by-1.25-mile (4-by-2-by-2-kilometer) invisible boundary around the orbiting laboratory. These demonstrations will be required before Dream Chaser can enter joint operations with the NASA team at the Mission Control Center in Houston. These include demonstrating attitude control, translational maneuvers, and abort capabilities.

Near-field demonstrations, which must happen closer to the space station, include activating and using light detection and ranging (LIDAR) sensors, responding to commands sent from the space station, retreating from the station when commanded, and holding its approach, first at 1,083 feet (330 meters), then 820 feet (250 meters), and finally, at 98 feet (30 meters) from the station. Following successful completion of the demonstrations, Dream Chaser will move towards the space station.

As Dream Chaser approaches the orbiting laboratory, it will hold a final time approximately 38 feet (11.5 meters) from the space station, when a station crew member will use Canadarm2 robotic arm to grapple a fixture on the spacecraft’s cargo module before teams on the ground install the cargo module to an Earth-facing port on the Unity or Harmony module.

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.

Return to Earth

Dream Chaser will remain at the space station for about 45 days before it is uninstalled using Canadarm2. The spacecraft can land as quickly as 11 to 15 hours after departure, and there are daily opportunities if weather criteria are met. Landing weather criteria for Dream Chaser generally require crosswinds at less than 17.2 miles per hour (15 knots), headwinds under 23 mph (20 knots), and tailwinds below 11.5 mph (10 knots). Thunderstorms, lightning, and rain within a 20-mile radius of the runway or 10 miles along the approach path are not acceptable conditions for landing. Detailed flight rules will guide controllers in determining whether landing opportunities are favorable.

A combination of Dream Chaser’s 26 reaction control system thrusters will fire to commit the spacecraft to deorbit. Dream Chaser will re-enter Earth’s atmosphere and glide to a runway landing at Kennedy’s Launch and Landing Facility in the style of NASA’s space shuttle, becoming the first spacecraft to land at the facility since the final space shuttle flight in 2011.

Once Dream Chaser is powered down after landing, the Sierra Space ground operations team will transfer it to the Space System Processing Facility to perform necessary inspections, off-load remaining NASA cargo, and begin the process of preparing it for the next mission.

Sierra Space, formerly Sierra Nevada Corporation, was selected in 2016 as NASA’s third commercial cargo resupply spacecraft to service the International Space Station

For updates on NASA’s commercial resupply services, visit:

https://www.nasa.gov/mission_pages/station/structure/launch/index.html

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      An E-3 Test Facility was constructed to support various component and small/subscale engine and booster test projects. Relativity Space leased a partially developed E-4 test area in 2018 and has since completed construction to support its commercial testing.
      All in all, the E Test Complex stands feature 12 active cells capable of various component and engine testing. The versatility of the complex infrastructure and test team allows it to support test projects for a range of commercial aerospace companies, large and small. Currently, both E-2 cells 1 and 2 are leased to Relativity Space through 2028.
      An aerial image shows the E-1 Test Stand at NASA’s Stennis Space Center on May 19, 2015. The versatile four-stand E Test Complex includes 12 active test cell positions capable of various component, engine, and stage test activities. NASA/Stennis An aerial image shows the E-3 test area at NASA’s Stennis Space Center on May 19, 2015. The versatile four-stand E Test Complex includes 12 active test cell positions capable of various component, engine, and stage test activities. NASA/Stennis An aerial image shows the E-2 Test Stand (Cell 1) at NASA’s Stennis Space Center on May 19, 2015. The versatile four-stand E Test Complex includes 12 active test cell positions capable of various component, engine, and stage test activities. NASA/Stennis “These facilities really do not exist anywhere else in the United States,” said Kevin Power, assistant director, Office of Project Management in the NASA Stennis Engineering and Test Directorate.  “Customers come to us with requirements for certain tests of an article, and we look at what is the best place to test it based on the facility infrastructure. We have completed component level testing, all the way up to full engines.”
      The list of companies who have conducted – or are now conducting – propulsion projects in the E Test Complex reads like a who’s who of commercial aerospace leaders.
      “The E Complex illustrates the NASA Stennis story,” Power said. “We have very valuable infrastructure and resources, chief of which is the test team, who adapt to benefit NASA and meet the needs of the growing commercial aerospace industry.”
      For information about NASA’s Stennis Space Center, visit:
      Stennis Space Center – NASA
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      Last Updated Nov 13, 2024 EditorNASA Stennis CommunicationsContactC. Lacy Thompsoncalvin.l.thompson@nasa.gov / (228) 688-3333LocationStennis Space Center Related Terms
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      Note: The following article is part of a series highlighting propulsion testing at NASA’s Stennis Space Center. To access the entire series, please visit: https://www.nasa.gov/feature/propulsion-powering-space-dreams/.
      An aerial image from 1965 shows the dual flame trenches of the Thad Cochran Test Stand (B-1/B-2) under construction at NASA’s Stennis Space Center (then known as Mississippi Test Operations) taking shape.NASA/Stennis Since the United States sent the first humans to the Moon more than 60 years ago, NASA’s Stennis Space Center near Bay St. Louis, Mississippi, has answered the call to help power the nation’s space dreams.  
      “History shows NASA Stennis is the country’s premier rocket engine test site and the go-to place for propulsion testing,” NASA Stennis Director John Bailey said. “It started with Apollo and continued through space shuttle. Now, we are going back to the Moon and beyond with Artemis – and it all comes through NASA Stennis.” 
      As the nation raced to send the first humans to the Moon, NASA selected a remote location in Hancock County, Mississippi, in October 1961 to test the needed rocket stages. Thanks to a massive construction project, the site conducted its first Saturn V rocket stage test in April 1966. In the next four-plus years, NASA Stennis tested 27 Saturn V stages, including those that launched 12 astronauts to walk on the Moon.  
      “Talking to people working here during those years, you hear how much they believed in the mission,” said Joe Schuyler, director of the NASA Stennis Engineering and Test Directorate. “Their hard work helped America reach the Moon and showed us the possibilities for NASA Stennis.”   
      Construction workers bring down a tree during the early days of construction for NASA’s Stennis Space Center. Tree-cutting to start what was the largest construction project in Mississippi – and one of the largest in the United States – at the time began May 17, 1963.NASA/Stennis NASA Stennis (then known as the Mississippi Test Facility) conducts its first-ever test firing – a 15-second hot fire of the Saturn V S-II-C second stage prototype – on the A-2 Test Stand on April 23, 1966.NASA/Stennis An aerial image from early 1967 shows the completed A-2 Test Stand in the foreground and the Thad Cochran Test Stand (B-1/B-2) in the background at NASA’s Stennis Space Center, then known as the Mississippi Test Facility.NASA/Stennis NASA officials view the first space shuttle main engine test on the Fred Haise Test Stand (formerly the A-1 Test Stand) at NASA’s Stennis Space Center (then known as National Space Technology Laboratories) on May 19, 1975.NASA/Stennis A 1979 image offers a close-up view of a space shuttle main propulsion test article hot fire on the B-2 side of the Thad Cochran Test Stand at NASA’s Stennis Space Center (then known as National Space Technology Laboratories). Main propulsion test article testing involved installing a shuttle fuel tank, a mockup of the shuttle orbiter and the vehicle’s three-engine configuration on the stand, then firing all three engines simultaneously, as would be done during an actual launch.NASA/Stennis As Apollo missions neared an end, plans were underway to drastically reduce the NASA Stennis footprint. Enter the space shuttle. NASA considered three locations to test engines for its new reusable vehicle before selecting NASA Stennis on March 1, 1970, ensuring the center’s future for the next several decades.  
      Space shuttle main engine testing proved challenging as the site transitioned from handling full rocket stages to firing single engines. “A big part of the challenge was the fact that teams were testing an entire engine from the very start,” NASA Test Operations Chief Maury Vander said. “Typically, you begin testing components, then progress to a full engine. Teams had a lot to learn in real time.” 
      NASA Stennis teams also tested the shuttle Main Propulsion Test Article with three engines firing simultaneously. The testing was particularly critical given the first shuttle mission would carry astronauts. 
      NASA Stennis teams worked diligently to demonstrate the shuttle system would operate safely, an effort characterized as one of the site’s finest hours. Following the first shuttle mission in 1981, astronauts Robert Crippen and John Young visited the south Mississippi site. “The effort that you contributed made it possible for us to sit back and ride,” Crippen told NASA Stennis employees. 
      From 1975 to 2009, NASA Stennis tested every main engine to help power 135 shuttle missions that enabled historic missions, such as those that deployed and repaired the Hubble Space Telescope and assembled the International Space Station, enabling its many scientific experiments and spinoff technologies. The site also tested every engine and component upgrade and helped troubleshoot performance issues. It led test campaigns following shuttle accidents to help ensure safe returns to flight. In total, the site conducted 2,307 tests for 820,475.68 seconds of accumulated hot fire. 
      NASA conducts the final test of a space shuttle main engine on the A-2 Test Stand at NASA’s Stennis Space Center on July 29, 2009. The Space Shuttle Program concluded two years later with the STS-135 shuttle mission.  NASA / Stennis An on-stand camera offers a closeup view of the first test of an RS-25 engine on the Fred Haise Test Stand (formerly the A-1 Test Stand) at NASA’s Stennis Space Center on Jan. 9, 2015. RS-25 engines power the core stage of NASA’s powerful SLS (Space Launch System) rocket.NASA/Stennis Crews at NASA’s Stennis Space Center install the first core stage of NASA’s powerful SLS (Space Launch System) on the B-2 side of the Thad Cochran Test Stand on Jan. 21-22, 2020. Following testing, the stage would help launch the Artemis I mission in November 2022.NASA/Stennis NASA conducts a full-duration RS-25 hot fire April 3, 2024, on the Fred Haise Test Stand at NASA’s Stennis Space Center, achieving a major milestone for future Artemis flights of NASA’s SLS (Space Launch System) rocket. It marked the final hot fire of a 12-test series to certify production of new RS-25 engines by lead contractor L3Harris (formerly known as Aerojet Rocketdyne) to help power NASA’s SLS rocket on Artemis missions to the Moon and beyond, beginning with Artemis V.NASA/Stennis Even as NASA Stennis tested main engines to power shuttle missions, the site led in testing next-generation engines, including the Fastrac, XRS-2200 linear aerospike, and J-2X. It also developed its E Test Complex, with multiple test stands and cells, to support a range of component and engine test projects, including those of commercial aerospace companies.
      A landmark agreement between NASA Stennis and Aerojet Rocketdyne (now known as L3Harris) in 1998 marked the site’s first test partnership with such a company. “That was the starting point,” said Vander. “Today, we are a preferred partner for multiple companies and test projects, large and small.” 
      NASA Stennis also is testing RS-25 engines and related systems to help power NASA’s SLS (Space Launch System) rocket on Artemis missions to the Moon. When the agency travels to Mars, it is expected the missions will launch with engines tested at the Mississippi site as well. 
      “The Gulf Coast of Mississippi helped achieve our space dreams of the past, and NASA Stennis continues supporting today’s dreams,” Bailey said. “It is a true testament to the expertise and dedication of our entire team and the incredible support of surrounding communities and the whole state.” 
      For information about NASA’s Stennis Space Center, visit: 
      Stennis Space Center – NASA 
      Share
      Details
      Last Updated Nov 13, 2024 EditorNASA Stennis CommunicationsContactC. Lacy Thompsoncalvin.l.thompson@nasa.gov / (228) 688-3333LocationStennis Space Center Related Terms
      Stennis Space Center Explore More
      5 min read NASA Stennis – An Ideal Place for Commercial Companies
      Article 13 mins ago 4 min read NASA Stennis Propulsion Testing Contributes to Artemis Missions
      Article 14 mins ago 5 min read NASA Stennis Test Team Supports Space Dreams with Proven Expertise
      Article 14 mins ago Keep Exploring Discover Related Stennis Topics
      Propulsion Test Engineering
      NASA Stennis Front Door
      Multi-User Test Complex
      Doing Business with NASA Stennis
      View the full article
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