Sierra Space, a leading commercial space-tech company, has announced that final testing and launch preparations for its Dream Chaser spaceplane and Shooting Star cargo module have commenced at NASA's Kennedy Space Center in Florida. The company is preparing for its inaugural mission to resupply the International Space Station (ISS) and has also inked an agreement with All Points Logistics for reprocessing the reusable spaceplane onsite in Florida on future missions.
Credit: Sierra Space
The Dream Chaser spaceplane and Shooting Star cargo module arrived at the Kennedy Space Center in May and are now being readied for final assembly, testing, and pre-launch processing inside the historic Space Systems Processing Facility (SSPF). The SSPF has played a significant role in the development of the International Space Station and has hosted numerous payloads that have traveled to space, contributing to key discoveries and scientific breakthroughs.
"We are on the cusp of achieving a major milestone for Sierra Space and the commercial space industry," said Tom Vice, CEO of Sierra Space. "The final testing and launch preparations of the first Dream Chaser happening inside such a historic NASA facility underscore the significance of our mission to revolutionize space transportation with an innovative new commercial spaceplane and the world's first true spaceliner."
The launch preparation process involves three primary areas of work: final assembly and system checks, continued environmental testing, and pre-launch processing. The Sierra Space team is working closely with NASA to ensure that all systems are functioning seamlessly and that the spacecraft is ready for its maiden voyage.
Final assembly and system checks include the installation of the remaining thermal protection system tiles, propulsion system closeout and leak testing, and electrical system checks. Continued environmental testing includes Electromagnetic Interference (EMI) and Electromagnetic Compatibility (EMC) testing, acoustic testing, and runway testing to verify Dream Chaser's differential braking system upon returning from space and landing at Space Florida's Launch and
Landing Facility (LLF) onsite at Kennedy.
Sierra Space performed acoustics tests of the Shooting Star module at KSC ahead of launch to the ISS. Credit: Sierra Space
Acoustic testing is a critical component of the environmental testing process, simulating the intense noise levels experienced during launch and re-entry. The test will subject the Dream Chaser spaceplane to sound pressure levels of up to 140 decibels, equivalent to the sound of a rocket launch. The test will verify that the spacecraft's structure and systems can withstand the intense noise and vibrations, ensuring the safety of the crew and cargo.
During the acoustic test, the Dream Chaser spaceplane will be placed in a specialized test chamber and subjected to a range of sound frequencies, simulating the various phases of launch and re-entry. The test will also evaluate the effectiveness of the spacecraft's acoustic protection systems, designed to reduce the noise levels inside the crew compartment.
Pre-launch processing involves getting the spacecraft ready for encapsulation in the rocket fairing and integration with the ULA Vulcan Centaur's systems. The Dream Chaser spaceplane will be launched on the Vulcan Centaur rocket and will carry cargo to the ISS before returning to Earth and landing on a runway.
In addition to the launch preparations, Sierra Space has announced a partnership with All Points Logistics for long-term ground processing of the Dream Chaser fleet post-mission. The partnership will enable Sierra Space to reap the benefits of All Points' planned Space Prep facility complex onsite at Kennedy Space Center, which will provide seamless support for spacecraft operations from the factory to the launch pad.
"All Points is excited to be a part of the Sierra Space team," said Phil Monkress, CEO of All Points Logistics. "Our Kennedy Space Center Complex will provide the flexibility needed to support a diverse range of future Dream Chaser missions."
The Space Prep facility complex will boast approximately 500,000 square feet of state-of-the-art infrastructure, providing turnkey propellant servicing and de-servicing, pre- and post-mission payload integration and servicing, extensive equipment storage, and dedicated control centers. The facility will also feature dual processing spaces to eliminate processing chokepoints and advanced technology to avoid facility evacuations during hazardous operations.
The Dream Chaser transportation system, which includes cargo delivery and return capability on the world's first commercial spaceplane, will add an entirely new dimension to NASA's Commercial Resupply Services missions. The winged Dream Chaser lands on a runway and will be the first spacecraft to do so on a return mission from the space station since Space Shuttle Atlantis in July 2011.
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