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Forum:Commercial Space - Military Space
Topic:Sierra Space Dream Chaser cargo system
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Robert PearlmancollectSPACE
Dream Chaser to launch on Vulcan Centaur for NASA cargo missions

A small commercial spaceplane contracted by NASA to bring cargo to and from the International Space Station now has its ride to orbit.

The Dream Chaser spacecraft, built and operated by Sierra Nevada Corporation (SNC), will lift off on resupply missions to the orbiting laboratory on United Launch Alliance (ULA) Vulcan Centaur rockets, officials with both companies announced Wednesday (Aug. 14). The uncrewed mini-space shuttle is expected to debut with the launch vehicle, now under development, in late 2021.

Robert PearlmanSierra Nevada Corporation (SNC) release
Dream Chaser Spacecraft Primary Structure Arrives in Colorado

Sierra Nevada Corporation (SNC) announces the arrival of the primary vehicle structure to the company's Colorado production facility, kicking off full assembly of the Dream Chaser® spacecraft ahead of its first mission for NASA in 2021. The structure is the largest piece of technology to make up Dream Chaser and the most advanced high-temperature composite spaceframe ever built.

"It's an extraordinary engineering and manufacturing accomplishment," said Eren Ozmen, chairwoman and president of SNC. "Our team has been looking forward to this day for a long time so that we can fully assemble America's spaceplane in preparation for its first mission for NASA."

The primary structure is a pressurized composite structure that will contain pressurized payloads heading to the International Space Station. The structure was manufactured by subcontractor Lockheed Martin and recently shipped from their Fort Worth, Texas facility to Louisville, Colorado, where Dream Chaser is being built and integrated by SNC.

"As the first building block of the spacecraft, it represents the first critical path hardware to be received in Colorado and launch of the assembly, integration and test (AI&T) phase of the program," said former NASA space shuttle commander, astronaut and retired USAF pilot Steve Lindsey, now senior vice president of strategy for SNC's Space Systems business area. "Dream Chaser is truly a state-of-art vehicle with cutting edge technology. This structure exemplifies its unique design and complexity."

Highlights about the design:

  • Uses advanced composite 3D woven assembly methods and represents the most advanced high-temperature composite spaceframe ever built.

  • Structure is about 30 feet long by 15 feet wide and approximately 6 feet high and weighs roughly 2,200 pounds.

  • Materials include carbon fiber reinforced polymers (CFRPs), more traditionally referred to as "composites."

  • The use of CFRP materials instead of aluminum and titanium alloys, lowers manufacturing costs for creating a unique, aerodynamically complex spaceframe design.

  • Composites decrease the amount of thermal protection required compared to an aluminum primary structure.

  • Advanced 3D woven construction minimize penetrations to the hot lower aeroshell.
Robert PearlmanSierra Nevada Corporation (SNC) release
SNC's "Shooting Star" Arrives at NASA's Kennedy Space Center

Sierra Nevada Corporation (SNC) delivered a test version of its Shooting Star cargo module to NASA's Kennedy Space Center for testing ahead of its planned launch with SNC's Dream Chaser spacecraft in 2021.

Shooting Star is a 15-foot attachment to Dream Chaser that will be used on NASA's Commercial Resupply Services 2 (CRS-2) contract to provide extra storage for payloads and to facilitate cargo disposal upon re-entry into Earth's atmosphere.

"With the addition of Shooting Star we add a capability for NASA, sending even more critical science, food and cargo to the International Space Station, and contributing to the important work the astronauts are doing every day," said Eren Ozmen, SNC's Chairwoman and President.

Dream Chaser will execute its first of at least six launches to the International Space Station in fall of 2021 under the CRS-2 contract. The cargo module will carry an additional 10,000 pounds of pressurized and unpressurized payloads to the International Space Station.

A key capability for Dream Chaser is performing cargo disposal upon re-entry. SNC's Shooting Star cargo modules will burn up in the earth's atmosphere, discarding unwanted material offloaded from the International Space Station.

"Shooting Star's ability to deliver additional cargo and provide a disposal service makes it and Dream Chaser extremely effective and versatile," said former NASA space shuttle commander and retired USAF pilot Steve Lindsey, now senior vice president of strategy for SNC's Space Systems business area.

For additional versatility, Shooting Star can support logistics services to other LEO destinations, including future commercial outposts, and for the lunar Gateway. SNC has also developed a concept for a free flying version that can act as a satellite to carry large payloads, with high-power capacity.

Robert PearlmanSierra Nevada Corporation (SNC) release
SNC's Dream Chaser Spaceplane Wings Arrive in Colorado

Sierra Nevada Corporation (SNC), the global aerospace and national security leader owned by Eren and Fatih Ozmen, uncrated both wings for its Dream Chaser spaceplane this month at the company's Louisville, Colorado production facility. The wings' arrival kicks off the much-anticipated integration phase of a beautiful and critical differentiator for Dream Chaser, the world's only spaceplane owned by a private company and under contract with NASA.

"The wings are here and now we truly have butterflies in anticipation of this integration phase for Dream Chaser," said SNC President Eren Ozmen. "Our spaceplane looks and functions unlike anything else in space – more technologically advanced but with all the heritage of the space shuttle program in its design. Dream Chaser's first flight will be a soaring moment for all of us."

The arrival kicks off the integration of the complex Wing Deployment System (WDS) as part of the continued assembly and integration of the vehicle. With their innovative folding design, the wings are stowed in the fairing ahead of launch. After the launch vehicle separates, the WDS deploys the wings and locks them into place. Dream Chaser's steeply angled wings function as stabilizers for the lift generated by the body of the vehicle.

"The wings for Dream Chaser presented an interesting design challenge," said Dream Chaser program director John Curry. "Not only must they survive in low-Earth orbit like a satellite, but they need to be operational in Earth's atmosphere, like an aircraft." Just like the structural body for Dream Chaser, the wings were manufactured by Lockheed Martin in Texas, a subcontractor to SNC, and are single bonded composite structures. This state-of-the-art technology saves weight without compromising strength and stiffness.

Dream Chaser is under contract with NASA for at least six cargo resupply and return service missions to the International Space Station under the Commercial Resupply Services 2 (CRS-2) contract. The Dream Chaser and attached Shooting Star transport vehicle can carry up to 12,000 pounds of supplies and other cargo, and returns delicate science to Earth with a gentle runway landing.

Robert PearlmanSierra Nevada Corporation (SNC) release
Dream Chaser Spaceplane First Orbital Vehicle New Name: Dream Chaser Tenacity

Sierra Nevada Corporation (SNC), the global aerospace and national security leader owned by Eren and Fatih Ozmen, marked National Space Day by announcing the name of its first orbital vehicle set to launch under contract with NASA: Dream Chaser Tenacity.

"Tenacity is in SNC's DNA," said SNC Chairwoman and President Eren Ozmen.

"Every critical moment in SNC's history of innovation has called for tenacity, in overcoming challenges in order to support and protect explorers and heroes. As the nation faces this current challenge, we want this vehicle to be a beacon of hope that American ingenuity – and tenacity – will bring brighter days ahead."

SNC's Dream Chaser spacecraft, known as "America's Spaceplane," is the world's only non-capsule, commercial spacecraft and is capable of a runway landing. Under a NASA contract, it will perform cargo delivery and disposal services to and from the International Space Station on at least six NASA missions.

"Dream Chaser is a story of grit and tenacity on the part of SNC's team," said John Curry, SNC's Program Director for Dream Chaser. "NASA's vision and ours for a next gen space shuttle with a gentle runway landing has weathered tough economic and budget resources and competing visions. The team and engineers working on Dream Chaser have believed in its superior design, knowing tenacity would lead to Dream Chaser flying in space and returning humans and science back to Earth safely."

NASA this week selected the Dynetics team, of which SNC is an integral part, to support its Artemis mission to the moon. SNC is leading development of the crew module for NASA's Human Landing System (HLS) program, which will ferry astronauts and supplies to and from the moon's surface. The program is designed to provide new science and material resources and leverage the moon as a proving ground for future Mars missions. NASA's goal is to land astronauts on the moon by 2024 and establish sustainable missions by 2028.

About Dream Chaser Spaceplane & Shooting Star Transport Vehicle

Owned and operated by SNC, the Dream Chaser spaceplane is a reusable, multi-mission space utility vehicle. It is capable of transportation services to and from low-Earth orbit and is the only commercial, lifting-body vehicle capable of a runway landing. The Dream Chaser Cargo System was selected by NASA to provide cargo delivery and disposal services to the International Space Station under the Commercial Resupply Services 2 (CRS-2) contract. All Dream Chaser CRS-2 cargo missions are planned to land at Kennedy Space Center's Shuttle Landing Facility. The Shooting Star cargo transport vehicle is a 15-foot attachment to Dream Chaser that provide extra storage for payloads, flexible mission options and facilitates cargo disposal upon re-entry into Earth's atmosphere.

Robert PearlmanSierra Nevada Corporation (SNC) release
SNC's Dream Chaser Spaceplane's Shooting Star Arrives in Colorado for Integration

Transport Vehicle Passed Critical Testing on Accelerated Timeline

Sierra Nevada Corporation (SNC), the global aerospace and national security leader owned by Eren and Fatih Ozmen, received its Shooting Star transport vehicle at the company's Colorado production facility, marking the beginning of a key integration phase. This phase includes installation of the SNC-built Passive Common Berthing Mechanism that will allow SNC's Dream Chaser Tenacity spaceplane, the first orbital vehicle in the company's Dream Chaser fleet, to berth to the International Space Station.

Above: SNC's Shooting Star Transport Vehicle for the Dream Chaser Spaceplane Arrives in Colorado.

Shooting Star is a 16-foot tall attachment to Dream Chaser that has capacity for more than 10,000 pounds of additional payloads to the International Space Station. It represents the first composite pressure vessel ever test-verified for visiting the International Space Station.

"This is a landmark milestone, not only for SNC, but for all of space exploration," said SNC owner and CEO, Fatih Ozmen. "This state-of-the-art, mission-ready structure is a testament to SNC's ability to deliver more capabilities to our customer without compromising on design."

Built primarily from advanced composite materials, Shooting Star has a high strength-to-weight ratio, allowing it to achieve a high payload capacity to the space station. The structure was manufactured by subcontractor Applied Composites to SNC's design requirements and recently shipped from its San Diego, California facility, to Louisville, Colorado, where it will be integrated by SNC.

"I am very proud of both Applied Composites and my team," said former NASA space shuttle commander and retired USAF pilot Steve Lindsey, now senior vice president of strategy for SNC's Space Systems business area. "Not only did they complete crucial testing for Shooting Star on an accelerated timeline ahead of Shooting Star's arrival in Louisville, but they innovated an entirely new approach to maintain the safety of both teams throughout the COVID-19 crisis."

Shooting Star will now undergo integration with its subsystems before being delivered to NASA's Plum Brook Station in Cleveland, Ohio for testing to ensure it can withstand both launch and space environments.

Dream Chaser is under contract with NASA for at least six cargo resupply and return service missions to the International Space Station under the Commercial Resupply Services 2 (CRS-2) contract. The Dream Chaser and attached Shooting Star transport vehicle can carry up to 12,000 pounds of supplies and other cargo, and returns delicate science to Earth with a gentle runway landing. Shooting Star also allows disposal services for the space station, and for these disposal missions, separates from Dream Chaser and disintegrates upon re-entry into Earth's atmosphere.

Robert PearlmanSierra Nevada Corporation (SNC) release
SNC's Dream Chaser Spaceplane Cleared for Florida Runway Landing

Sierra Nevada Corporation (SNC) has entered into a Use Agreement for Space Florida's Launch and Landing Facility (LLF) to land the Dream Chaser spaceplane in support of NASA's Commercial Resupply Services-2 (CRS-2) contract. Dream Chaser, America's Spaceplane, will service the International Space Station (ISS) under the CRS-2 contract in 2022.

"This is a monumental step for both Dream Chaser and the future of space travel," said SNC CEO Fatih Ozmen. "To have a commercial vehicle return from the International Space Station to a runway landing for the first time since NASA's space shuttle program ended a decade ago will be a historic achievement."

The Use Agreement makes SNC the first commercial user of Space Florida's FAA Re-entry Site Operator License and provides the runway and support facilities needed during testing and landing. It also takes SNC one step further in applying for its own FAA re-entry license, something needed ahead of the first Dream Chaser mission next year.

"The Dream Chaser spaceplane is hands-down the best way home," said Janet Kavandi, executive vice president of SNC's Space Systems business area. "A runway landing is the optimum solution for both humans and science."

Dream Chaser has the potential to land at any FAA licensed landing site that has a suitable 10,000-foot runway capable of handling a typical commercial jet. Its low-g entry and runway landing protects sensitive payloads and provides immediate access to payloads upon landing.

The LLF's proximity to Kennedy Space Center and formal recognition as a designated return site for rapid recovery of precious ISS cargo makes it the ideal location for the first orbital vehicle in SNC's Dream Chaser fleet, the Dream Chaser Tenacity spaceplane to make its debut landing.

SNC recently announced its Space Systems Group will transition to an independent commercial space company, Sierra Space.

Robert PearlmanSierra Space release
Sierra Space's Dream Chaser® Spaceplane Comes to Life

Dream Chaser, the World's First Commercial Spaceplane, Powers Up Achieving a Major Step Forward in Realizing the Vision of Sustainable Commercial Space Travel

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.

Robert PearlmanSierra Space release
Today Sierra Space Introduces Tenacity

Sierra Space today (Nov. 2) 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.

Robert PearlmanSierra Space release
Sierra Space Dream Chaser Spaceplane Successfully Completes First Phase of Pre-Flight Testing

Sierra Space, a leading commercial space company and emerging defense tech prime building a platform in space to benefit and protect life on Earth, announced today the successful completion of the initial phase of environmental testing on the revolutionary Dream Chaser® spaceplane, Tenacity®, at NASA's Neil Armstrong Test Facility in Sandusky, Ohio.

Over the past month, the Sierra Space Dream Chaser and its cargo companion, Shooting Star™, underwent rigorous vibration testing while stacked in launch configuration inside the Mechanical Vibration Facility at the NASA complex. In readiness for launch from Kennedy Space Center, the tests exposed the vehicles to the intense conditions of launch vibrations using the world's most powerful spacecraft shaker table.

"We are coming out of years of development, years of hard work and years of resolving tough engineering challenges that come from revolutionary new ways of doing things," said Sierra Space CEO Tom Vice. "This phase of development illustrates how Dream Chaser and the Shooting Star cargo module will handle the mechanical rigors of launch. This is the year that we transition from development and enter orbital operations – it is the year that changes how we connect space and earth."

"Completion of vibration testing of the vehicles in the launch configuration is a huge milestone for Sierra Space and the Dream Chaser program," said Jake Ingram, Director of Programs for Dream Chaser DC-100. "We successfully applied the environment specified by the launch provider, validated primary structure modal responses and verified vehicle functionality before and after the vibration test sequence."

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).

'Joint Test #3', a critical phase in the testing process, represented an integrated assessment of the completed system in a flight-like configuration. After its ride to space atop United Launch Alliance's Vulcan Centaur rocket, Dream Chaser separates from the rocket fairing, deploys its wings from a folded position and flies semi-autonomously to the International Space Station. Joint Test #3 was a comprehensive evaluation focused on the software interface between the vehicle and the ISS to ensure the seamless functionality of the command and data handling.

Following these critical test phases, the Shooting Star cargo module was de-mated from Dream Chaser and transported from the Armstrong Test Facility's Space Environments Complex (SEC) to the nearby In-Space Propulsion (ISP) facility. Soon, Dream Chaser will be transported to the ISP facility to join the cargo module, where the two spacecraft will begin thermal vacuum testing, a crucial step in the journey towards the launchpad and another milestone in Sierra Space's mission to redefine the future of space commercialization.

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