More Updates As Sierra Space Continues To Make Progress On Dream Chaser
As Dream Chaser’s first launch gets closer and closer, so have the updates and progress on the spacecraft from Sierra Space. This spaceplane is expected to change how we access space and provide one of a kind features. While in the last few months we were provided a few sneak peeks at the test articles and their progress, now we are getting even more.
Just yesterday Sierra Space released a new image showing off the Dream Chaser test article with quite a few thermal tiles installed. Decades ago the Space Shuttle performed over 100 missions but had a few problems as well. In this case, Sierra Space is trying to create a modern spaceplane that innovates on past experiences and lessons learned.
However, this spacecraft still features a very ambitious design that has yet to be tested on an actual launch. A fact the company is working to change with the first launch scheduled less than one year away in the third quarter of 2023. Here I will go more in-depth into the recent update, the differences between Dream Chaser and the Space Shuttle, what to expect in the future, and more.
Dream Chaser Thermal Tiles
Just over a month ago, Sierra Space gave an update on Dream Chaser highlighting that their team is currently working to install thousands of thermal tiles on Tenacity. Thankfully, just yesterday we got the first official look at this process with another update from the company. Specifically, yesterday Sierra Space tweeted saying, “As Sierra Space prepares Dream Chaser for missions to the International Space Station in 2023, we move another step forward in realizing our team’s mission to build a platform in space to benefit life on Earth.” Here you could see what should Dream Chaser Tenacity partially disassembled for the application of thermal tiles. Taking a closer look at the image, it reveals hundreds of different tiles, each with specific markings and writing. With this test article being a cargo variant, there are no windows and instead, this entire front section is full of tiles.
Currently, Sierra Space and NASA are still targeting the third quarter of 2023 for Dream Chaser’s first mission to space and trip to the International Space Station. The mission is named SNC-DEMO 1 and is intended to be a demonstration flight of Dream Chaser to ISS for NASA, with a duration of around 82 days. Since Dream Chaser is only a spacecraft, it needs a dedicated launch vehicle in order to reach orbit. For this first mission, ULA’s Vulcan Centaur is still scheduled to be the rocket responsible for the job. However, if necessary, there are additional options for launching the spacecraft which helps improve its future opportunities.
In addition to this update on the installation of thermal tiles, not long ago, Sierra Space released new information on some of the final preparation being made for this first mission. In late October the company tweeted highlighting, “At Sierra Space the countdown clock has already started. Preparing for the actual moment – go for launch. This is mission control.” This included a video that went over the process inside mission control and some of the simulations and tests being performed that directly apply to Tenacity’s upcoming mission.
Under NASA’s Commercial Resupply Services 2 (CRS-2) contract, Dream Chaser will deliver more than 12,000 pounds of pressurized and unpressurized cargo to the space station and remains attached for up to 75 days as an orbiting laboratory. Once the mated mission is complete, the Dream Chaser disposes about 7,000 pounds of space station trash and returns large quantities of critical science, accessible within minutes after a gentle runway landing. This will be Tenacity’s job not long from now. As partially mentioned prior, the first mission is set to happen on top of ULA’s Vulcan. Due to the fact that this is an uncrewed mission, Dream Chaser Tenacity will launch within Vulcan’s fairings, and fold its wings in order to fit. For future crewed missions, Dream Chaser is expected to launch with no fairings allowing for an abort capability if something were to go wrong.
Dream Chaser’s Design
Now that we know more about Tenacity’s first mission right around the corner, we can take a closer look at Dream Chaser and some of its important features. For one, the recent updates regarding Dream Chaser’s thermal tiles are important to consider. In the past, one of the big downfalls of the Space Shuttle was its thermal tiles. Besides the fact that in certain instances they were damaged which caused devastating results, one of the main issues had to do with reusability. During Shuttle launches, tiles would often come off or would be damaged and had to be replaced. This process ended up being one of the sole reasons that continued to delay the spacecraft. To put it in perspective, each tile used cement that required 16 hours to cure. After the tile was affixed to the cement, a jack held it in place for another 16 hours. In March 1979 it took each worker 40 hours to install one tile. As you can imagine, this was a big oversight that caused various problems over time.
In the case of Dream Chaser, Sierra Space is confident that its design significantly improves on the ideas and technology applied to the Shuttle. For one, in total there are around 2,000 thermal tiles across the entire spacecraft when complete. In comparison, the Space Shuttle featured more than 21,000 tiles. In addition, Sierra Space points out that their thermal tiles are both strong and lighter weight than what was used during the shuttle program. The company is also using more modern manufacturing techniques to increase strength and reduce cost. TPS tiles protect the vehicle from re-entry heat. Altogether these tiles will protect Dream Chaser from temperatures that could reach upwards of 3,000°F on entry, while keeping the vehicle itself at only 350°F. The white tiles reject more heat from the sun while on-orbit, which helps to keep the components within Dream Chaser cooler. All of which is hoping to create an overall highly improved product and process in future Dream Chaser spacecraft.
In the past, Dream Chaser was originally designed as a crewed spaceplane, in part under NASA’s Commercial Crew Program, capable of carrying up to seven astronauts to and from the space station and other low Earth orbit (LEO) destinations. Dream Chaser is 30 feet, or 9 meters long—around ¼ the total length of the space shuttle orbiters—and can carry up to seven crew members. The crewed version of Dream Chaser is approximately 85% common to the cargo system, limiting primary changes to windows, environmental control, and life support systems. In addition, an integral main propulsion system is available for abort capability and major orbital maneuvers. This also determines whether or not it launches with or without a faring as partially mentioned prior.
While the first uncrewed mission is scheduled late next year, the first crewed Dream Chaser launch is quite far away. As of 2020, the Sierra Nevada Corporation says it still plans to produce a crewed version of the spacecraft within the next 5 years. The company says it “never stopped working” on the crewed version and fully intends to launch it after the cargo version, and is still committed to the crewed version. Not to mention, in November 2021, Sierra Nevada Corporation reported that it received a $1.4 billion investment in Series A funding, which it will use to develop a crewed version of Dream Chaser and fly astronauts in the future.
On the other hand, under NASA’s Commercial Resupply Services 2 (CRS-2) contract, Dream Chaser will provide a minimum of seven cargo service missions to and from the space station. With the help of our Shooting Star™ service module, Dream Chaser can deliver up to 5,500 kg of pressurized and unpressurized cargo to the space station, including food, water, supplies, and science experiments, then return to Earth. Shooting Star adds a service for NASA to send additional critical science, food, and cargo to the space station. Traveling through the Shooting Star takes them to the forward portion where they can open the hatch and gain access to the Dream Chaser. When attached to the space station, Shooting Star provides a normal cabin environment for astronauts to work, and a prime location for cargo to be removed and placed onto the station after berthing.
Dream Chaser can return critical cargo at less than 1.5 g’s using a gentle runway landing. Designed for high reusability, this vehicle reduces overall cost, providing quick turnarounds between missions. The ability to liftoff on top of multiple launch vehicles and land at a wide variety of runways makes Dream Chaser a flexible option for reliable transportation. After leaving the space station, the Dream Chaser Cargo System also offers disposal services via the Shooting Star transport vehicle. Once separated from Dream Chaser, Shooting Star burns up safely in Earth’s atmosphere. As time goes on we will have to keep an eye on the multiple Dream Chaser test articles and their progress.
Conclusion
Sierra Space is working hard to prepare for the first official Dream Chaser missions scheduled in the third quarter of 2023. Right now the company is installing thermal tiles on Tenacity which will be the first test article to attempt the mission. We will have to wait and see how it progresses and the impact it has on the space industry.