Space

against-all-odds,-an-asteroid-mining-company-appears-to-be-making-headway

Against all odds, an asteroid mining company appears to be making headway

Forging ahead —

“It’s not easy to ever raise for an asteroid mining company, right?”

The Odin spacecraft passed vibration testing.

Enlarge / The Odin spacecraft passed vibration testing.

Astro Forge

When I first spoke with space entrepreneurs Jose Acain and Matt Gialich a little more than two years ago, I wondered whether I would ever talk to them again.

That is not meant to be offensive; rather, it is a reflection of the fact that the business they entered into—mining asteroids for platinum and other precious metals—is a perilous one. To date, NASA and other space agencies have spent billions of dollars returning a few grams of rocky material from asteroids. Humanity has never visited a metal-rich asteroid, although that will finally change with NASA’s $1.4 billion Psyche mission in 2029. And so commercial asteroid mining seems like a stretch, and indeed, other similarly minded startups have come and gone.

But it turns out that I did hear from Acain and Gialich again about their asteroid mining venture, AstroForge. On Tuesday the co-founders announced that they have successfully raised $40 million in Series A funding and shared plans for their next two missions. AstroForge has now raised a total of $55 million to date.

“It was challenging,” Gialich said of the latest fundraising effort, in an interview. “It’s not easy to ever raise for an asteroid mining company, right? Let’s be honest. We talked two years ago and you told us this. And you were not wrong. So a big part of this funding round was just showing people that we can actually build a spacecraft.”

Making some mistakes

In April 2023, the company launched a shoebox-sized cubesat, named the Brokkr-1 mission, on a SpaceX Transporter flight. Although the vehicle flew as intended for a while, AstroForge was unable to send the necessary commands to the spacecraft to initiate a demonstration of its space-based refining technology.

However, Gialich said AstroForge learned a lot from this mission and is working toward launching a second spacecraft named Odin. This will be a rideshare payload on the Intuitive Machines-2 mission, which is due to launch during the fourth quarter of this year. If successful, the Odin mission would be spectacular. About seven months after launching, Odin will attempt to fly by a near-Earth, metallic-rich asteroid while capturing images and taking data—truly visiting terra incognita. Odin would also be the first private mission to fly by a body in the Solar System beyond the Moon.

It has not been an easy project to develop. In the name of expediency, AstroForge initially sought to develop this spacecraft by largely outsourcing key components from suppliers—a practice known as horizontal integration. However, in March, the Odin spacecraft failed vibration testing. “Originally, our concept was to be different than SpaceX, and be horizontally integrated, not vertical,” Gialich said. “That was completely wrong. We have very much made changes there to be vertical.”

After the original vehicle failed vibration testing, which ensures it can survive the rigors of launch, AstroForge decided to bring forward a spacecraft being developed internally for the company’s third flight and use that for the Odin mission. To remain on track for a launch this year, the company had to complete vibration testing of the new, 100-kg Odin vehicle by August 1. AstroForge made that deadline but still must complete several other tests before shipping Odin to the launch pad.

Docking with an asteroid

On Tuesday, the company also announced plans for its third mission, Vestri (the company is naming its missions after Norse deities). This spacecraft will be about twice as large as Odin and is intended to return to the targeted metallic asteroid and dock with it. The docking mechanism is simple—since the asteroid is likely to be iron-rich, Vestri will use magnets to attach itself.

The plan is to use a mass spectrometer to sample and characterize the asteroid weekly until the spacecraft fails. AstroForge seeks to launch Vestri on another Intuitive Machines mission in 2025. Vestri’s goals are highly ambitious, as no private spacecraft has ever landed on a body beyond the Moon.

AstroForge is tracking several candidate asteroids as the target body for Odin and Vestri, Gialich said, each of which is about 400 meters across. He won’t make a final decision for several months. The company does not want to tip its hand due to the interest of potential competitors, including China-based Origin Space.

However, there is no shortage of potential targets. Scientists estimate that there are about 10 million near-Earth asteroids, which come within one astronomical unit (the distance between the Sun and Earth) of our planet. Perhaps 3 to 5 percent of these are rich in metals, so there are potentially hundreds of thousands of candidates for mining.

Against all odds, an asteroid mining company appears to be making headway Read More »

rocket-lab-entered-“hero-mode”-to-finish-mars-probes—now-it’s-up-to-blue-origin

Rocket Lab entered “hero mode” to finish Mars probes—now it’s up to Blue Origin

The two spacecraft for NASA's ESCAPADE mission at Rocket Lab's factory in Long Beach, California.

Enlarge / The two spacecraft for NASA’s ESCAPADE mission at Rocket Lab’s factory in Long Beach, California.

Two NASA spacecraft built by Rocket Lab are on the road from California to Florida this weekend to begin preparations for launch on Blue Origin’s first New Glenn rocket.

These two science probes must launch between late September and mid-October to take advantage of a planetary alignment between Earth and Mars that only happens once every 26 months. NASA tapped Blue Origin, Jeff Bezos’ space company, to launch the Escape and Plasma Acceleration and Dynamics Explorers (ESCAPADE) mission with a $20 million contract.

Last November, the space agency confirmed the $79 million ESCAPADE mission will launch on the inaugural flight of Blue Origin’s New Glenn rocket. With this piece of information, the opaque schedule for Blue Origin’s long-delayed first New Glenn mission suddenly became more clear.

The launch period opens on September 29. The two identical Mars-bound spacecraft for the ESCAPADE mission, nicknamed Blue and Gold, are now complete. Rocket Lab announced Friday that its manufacturing team packed the satellites and shipped them from their factory in Long Beach, California. Over the weekend, they arrived at a clean room facility just outside the gates of NASA’s Kennedy Space Center in Florida, where technicians will perform final checkups and load hydrazine fuel into both spacecraft, each a little more than a half-ton in mass.

Then, if Blue Origin is ready, ground teams will connect the ESCAPADE spacecraft with the New Glenn’s launch adapter, encapsulate the probes inside the payload fairing, and mount them on top of the rocket.

“There’s a whole bunch of checking and tests to make sure everything’s OK, and then we move into fueling, and then we integrate with the launch vehicle. So it’s a big milestone,” said Rob Lillis, the mission’s lead scientist from the University of California Berkeley’s Space Science Laboratory. “There have been some challenges along the way. This wasn’t easy to make happen on this schedule and for this cost. So we’re very happy to be where we are.”

Racing to the finish line

But there’s a lot for Blue Origin to accomplish in the next couple of months if the New Glenn rocket is going to be ready to send the ESCAPADE mission toward Mars in this year’s launch period. Blue Origin has not fully exercised a New Glenn rocket during a launch countdown, hasn’t pumped a full load of cryogenic propellants into the launch vehicle, and hasn’t test-fired a full complement of first stage or second stage engines.

These activities typically take place months before the first launch of a large new orbital-class rocket. For comparison, SpaceX test-fired its first fully assembled Falcon 9 rocket on the launch pad about three months before its first flight in 2010. United Launch Alliance completed a hot-fire test of its new Vulcan rocket on the launch pad last year, about seven months before its inaugural flight.

However, Blue Origin is making visible progress toward the first flight of New Glenn, after years of speculation and few outward signs of advancement. Earlier this year, the company raised a full-scale, 320-foot-tall (98-meter) New Glenn rocket on its launch pad at Cape Canaveral Space Force Station and loaded it with liquid nitrogen, a cryogenic substitute for the methane and liquid hydrogen fuel it will burn in flight.

Rocket Lab entered “hero mode” to finish Mars probes—now it’s up to Blue Origin Read More »

rocket-report:-ula-is-losing-engineers;-spacex-is-launching-every-two-days

Rocket Report: ULA is losing engineers; SpaceX is launching every two days

Every other day —

The first missions of Stoke Space’s reusable Nova rocket will fly in expendable mode.

A Falcon 9 booster returns to landing at Cape Canaveral Space Force Station following a launch Thursday with two WorldView Earth observation satellites for Maxar.

Enlarge / A Falcon 9 booster returns to landing at Cape Canaveral Space Force Station following a launch Thursday with two WorldView Earth observation satellites for Maxar.

Welcome to Edition 7.07 of the Rocket Report! SpaceX has not missed a beat since the Federal Aviation Administration gave the company a green light to resume Falcon 9 launches after a failure last month. In 19 days, SpaceX has launched 10 flights of the Falcon 9 rocket, taking advantage of all three of its Falcon 9 launch pads. This is a remarkable cadence in its own right, but even though it’s a small sample size, it is especially impressive right out of the gate after the rocket’s grounding.

As always, we welcome reader submissions. If you don’t want to miss an issue, please subscribe using the box below (the form will not appear on AMP-enabled versions of the site). Each report will include information on small-, medium-, and heavy-lift rockets as well as a quick look ahead at the next three launches on the calendar.

A quick turnaround for Rocket Lab. Rocket Lab launched its 52nd Electron rocket on August 11 from its private spaceport on Mahia Peninsula in New Zealand, Space News reports. The company’s light-class Electron rocket deployed a small radar imaging satellite into a mid-inclination orbit for Capella Space. This was the shortest turnaround between two Rocket Lab missions from its primary launch base in New Zealand, coming less than nine days after an Electron rocket took off from the same pad with a radar imaging satellite for the Japanese company Synspective. Capella’s Acadia 3 satellite was originally supposed to launch in July, but Capella requested a delay to perform more testing of its spacecraft. Rocket Lab swapped its place in the Electron launch sequence and launched the Synspective mission first.

Now, silence at the launch pad … Rocket Lab hailed the swap as an example of the flexibility provided by Electron, as well as the ability to deliver payloads to specific orbits that are not feasible with rideshare missions, according to Space News. For this tailored launch service, Rocket Lab charges a premium launch price over the price of launching a small payload on a SpaceX rideshare mission. However, SpaceX’s rideshare launches gobble up the lion’s share of small satellites within Rocket Lab’s addressable market. On Friday, a Falcon 9 rocket is slated to launch 116 small payloads into polar orbit. Rocket Lab, meanwhile, projects just one more launch before the end of September and expects to perform 15 to 18 Electron launches this year, a record for the company but well short of the 22 it forecasted earlier in the year. Rocket Lab says customer readiness is the reason it will be far short of projections.

The easiest way to keep up with Eric Berger’s space reporting is to sign up for his newsletter, we’ll collect his stories in your inbox.

Defense contractors teaming up on solid rockets. Lockheed Martin and General Dynamics are joining forces to kickstart solid rocket motor production, announcing a strategic teaming agreement today that could see new motors roll off the line as early as 2025, Breaking Defense reports. The new agreement could position a third vendor to enter into the ailing solid rocket motor industrial base, which currently only includes L3Harris subsidiary Aerojet Rocketdyne and Northrop Grumman in the United States. Both companies have struggled to meet demands from weapons makers like Lockheed and RTX, which are in desperate need of solid rocket motors for products such as Javelin or the PAC-3 missiles used by the Patriot missile defense system.

Pressure from startups … Demand for solid rocket motors has skyrocketed since Russia’s invasion of Ukraine as the United States and its partners sought to backfill stocks of weapons like Javelin and Stinger, as well as provide motors to meet growing needs in the space domain. Although General Dynamics has kept its interest in the solid rocket motor market quiet until now, several defense tech startups, such as Ursa Major Technologies, Anduril, and X-Bow Systems, have announced plans to enter the market. (submitted by Ken the Bin)

Going polar with crew. SpaceX will fly the first human spaceflight over the Earth’s poles, possibly before the end of this year, Ars reports. The private Crew Dragon mission will be led by a Chinese-born cryptocurrency entrepreneur named Chun Wang, and he will be joined by a polar explorer, a roboticist, and a filmmaker whom he has befriended in recent years. The “Fram2” mission, named after the Norwegian research ship Fram, will launch into a polar corridor from SpaceX’s launch facilities in Florida and fly directly over the north and south poles. The three- to five-day mission is being timed to fly over Antarctica near the summer solstice in the Southern Hemisphere, to afford maximum lighting.

Wang’s inclination is Wang’s prerogative … Wang told Ars he wanted to try something new, and flying a polar mission aligned with his interests in cold places on Earth. He’s paying the way on a commercial basis, and SpaceX in recent years has demonstrated it can launch satellites into polar orbit from Cape Canaveral, Florida, something no one had done in more than 50 years. The highest-inclination flight ever by a human spacecraft was the Soviet Vostok 6 mission in 1963 when Valentina Tereshkova’s spacecraft reached 65.1 degrees. Now, Fram2 will fly repeatedly and directly over the poles.

Rocket Report: ULA is losing engineers; SpaceX is launching every two days Read More »

facing-“financial-crisis,”-russia-on-pace-for-lowest-launch-total-in-6-decades

Facing “financial crisis,” Russia on pace for lowest launch total in 6 decades

SMO fallout —

“This forces us to build a new economy in severe conditions.”

A Soyuz 2.1b rocket booster with a Frigate upper stage block, the Meteor-M 2-1 meteorological satellite, and 18 small satellites launched from the Vostochny Cosmodrome.

Enlarge / A Soyuz 2.1b rocket booster with a Frigate upper stage block, the Meteor-M 2-1 meteorological satellite, and 18 small satellites launched from the Vostochny Cosmodrome.

Yuri Smityuk/TASS

A Progress cargo supply spacecraft launched from the Baikonur Cosmodrome in Kazakhstan early on Thursday, local time. The mission was successful, and Russia has launched hundreds of these spacecraft before. So it wasn’t all that big of a deal, except for one small detail: This was just Russia’s ninth orbital launch of the year.

At this pace, it appears that the country’s space program is on pace for the fewest number of Russian or Soviet space launches in a year since 1961. That was when Yuri Gagarin went to space at the dawn of the human spaceflight era.

There are myriad reasons for this, including a decision by Western space powers to distance themselves from the Russian space corporation, Roscosmos, after the invasion of Ukraine. This has had disastrous effects on the Russian space program, but only recently have we gotten any insight into how deep those impacts have cut.

In recent weeks, the first deputy director of Roscosmos, Andrei Yelchaninov, has given a series of interviews to Russian news outlets. (Most Russian media are state-owned or state-controlled, so none of this information can be independently verified, but it is interesting nonetheless.) One of the most revealing of these interviews was given to national news agency Interfax. It was translated for Ars by Rob Mitchell and provides perspective on Russia’s space crisis and how the country will seek to rebound.

A financial crisis

“We are in an ongoing process of emerging from financial crisis, and it’s complicated,” Yelchaninov told Interfax. “I would remind you that contract cancellations by unfriendly contacts cost Roscosmos 180 billion rubles ($2.1 billion US). This forces us to build a new economy in severe conditions.”

As a result of this, Russia’s space industry has been operating at a loss in recent years and may not begin to break even until 2025. Russia’s invasion of Ukraine also came as United Launch Alliance finally ended its practice of purchasing RD-180 rocket engines, manufactured by NPO Energomash. This fact, in concert with decreased commercial demand for Russia’s Proton and Soyuz rockets, has forced the Russian government to subsidize these elements of Roscosmos.

These companies “are currently in a financial revitalization procedure and have received State subsidies several years ago in order to maintain viability, and are now seeking new sales markets and additional workload,” Yelchaninov said. Asked about possibly selling more Russian-made engines to the United States, Yelchaninov replied, “That issue is not on the agenda.”

Russia had to look to new sales markets after what Yelchaninov euphemistically refers to as the “special military operation,” which is Russia’s term of art for its war against Ukraine. “After the beginning of the SMO we were forced to shift from our traditional partners in Europe and the US, with whom we had many years of interaction, for new international directions including the countries in Africa, the Mideast, and Southeast Asia,” he said.

During the interview, Yelchaninov confirmed that Russia has committed to participating in the International Space Station program until “at least” 2028. NASA is pushing to extend the operational lifetime of the station to 2030, at which point the United States plans to de-orbit the aging laboratory using a modified Crew Dragon spacecraft.

Rather than working with the United States in space, Yelchaninov said that Russia’s space program would focus on cooperation with China rather than competition there. “The key project of our bilateral cooperation is creating an International Lunar Station to which we are jointly striving to attract additional international partners,” he said.

Big plans, big delays?

In addition, Russia is also continuing the development of its oft-delayed “Russian Orbital Station,” or ROS. The current plans call for the launch of a scientific and power module in 2027, with the core of the station (four modules) to be launched into orbit by 2030. Further expansions will take place in the early 2030s. It should be noted, however, that these dates can charitably be described as aspirational.

Even more speculatively, Yelchaninov mentioned several future rocket projects, including the Amur-LNG vehicle and the Corona rocket.

In 2020, Russia aimed to debut the methane-powered Amur rocket with a reusable first stage by 2026. This vehicle was developed to be cost-competitive with SpaceX’s Falcon 9 rocket. Yelchaninov now said Roscosmos intends to develop first-stage reuse in two phases. In the first of these, a Grasshopper-like program would test landing technologies before moving to experiments with a complete booster. But don’t expect to see Amur any time soon. Yelchaninov revealed that Russian and Kazakh officials are still in the design phase of a launch site at Baikonur, rather than actively building anything.

Yelchaninov also said Roscosmos would like to develop a single-stage-to-orbit rocket named Corona in the future. This appears to be an updated take on a Russian rocket design that is more than three decades old.

“We have already studied whether or not a new booster of this type will be in demand,” Yelchaninov said. “The answer is obvious—we are reducing the cost of access to space by more than an order of magnitude and discovering entirely new opportunities for super-operational delivery of cargo, and we are moving toward an ideology of space as a service.”

I would not hold my breath on seeing Corona fly.

Facing “financial crisis,” Russia on pace for lowest launch total in 6 decades Read More »

nasa-shuts-down-asteroid-hunting-telescope,-but-a-better-one-is-on-the-way

NASA shuts down asteroid-hunting telescope, but a better one is on the way

Prolific —

The NEOWISE spacecraft is on a course to fall out of orbit in the next few months.

Artist's illustration of NASA's Wide-field Infrared Survey Explorer spacecraft.

Enlarge / Artist’s illustration of NASA’s Wide-field Infrared Survey Explorer spacecraft.

Last week, NASA decommissioned a nearly 15-year-old spacecraft that discovered 400 near-Earth asteroids and comets, closing an important chapter in the agency’s planetary defense program.

From its position in low-Earth orbit, the spacecraft’s infrared telescope scanned the entire sky 23 times and captured millions of images, initially searching for infrared emissions from galaxies, stars, and asteroids before focusing solely on objects within the Solar System.

Wising up to NEOs

The Wide-field Infrared Survey Explorer, or WISE, spacecraft launched in December 2009 on a mission originally designed to last seven months. After WISE completed checkouts and ended its primary all-sky astronomical survey, NASA put the spacecraft into hibernation in 2011 after its supply of frozen hydrogen coolant ran out, reducing the sensitivity of its infrared detectors. But astronomers saw that the telescope could still detect objects closer to Earth, and NASA reactivated the mission in 2013 for another decade of observations.

The reborn mission was known as NEOWISE (Near-Earth Object Wide-field Infrared Survey Explorer). Its purpose was to use the spacecraft’s infrared vision to detect faint asteroids and comets on trajectories that bring them close to Earth.

“We never thought it would last this long,” said Amy Mainzer, NEOWISE’s principal investigator from the University of Arizona and UCLA.

Ground controllers at NASA’s Jet Propulsion Laboratory in California sent the final command to the NEOWISE spacecraft on August 8. The spacecraft, currently at an altitude of about 217 miles (350 kilometers), is falling out of orbit as atmospheric drag slows it down. NASA expects the spacecraft will reenter the atmosphere and burn up before the end of this year, a few months earlier than expected, due to higher levels of solar activity, which causes expansion in the upper atmosphere. The satellite doesn’t have its own propulsion to boost itself into a higher orbit.

“The Sun’s just been incredibly quiet for many years now, but it’s picking back up, and it was the right time to let it go,” Mainzer told Ars.

Astronomers have used ground-based telescopes to discover most of the near-Earth objects detected so far. But there’s an advantage to using a space-based telescope, because Earth’s atmosphere absorbs most of the infrared energy coming from faint objects like asteroids.

With ground-based telescopes, astronomers are “predominantly seeing sunlight reflecting off the surfaces of the objects,” Mainzer said. NEOWISE measures thermal emissions from the asteroids, giving scientists information about their sizes. “We can actually get pretty good measurements of size with relatively few infrared measurements,” she said.

The telescope on NEOWISE was relatively modest in size, with a 16-inch (40-centimeter) primary mirror, more than 16 times smaller than the mirror on the James Webb Space Telescope. But its wide field of view allowed NEOWISE to scour the sky for infrared light sources, making it well-suited for studying large populations of objects. One of the mission’s most famous discoveries was a comet officially named C/2020 F3, more commonly known as Comet NEOWISE, which became visible to the naked eye in 2020. As the comet moved closer to Earth, large telescopes like Hubble were able to take a closer look.

“The NEOWISE mission has been an extraordinary success story as it helped us better understand our place in the universe by tracking asteroids and comets that could be hazardous for us on Earth,” said Nicola Fox, associate administrator of NASA’s science mission directorate.

What’s out there?

The original mission of WISE and the extended survey of NEOWISE combined to discover 366 near-Earth asteroids and 34 comets, according to the Center for Near-Earth Object Studies. Of these, 64 were classified as potentially hazardous asteroids, meaning they come within 4.65 million miles (7.48 million kilometers) of Earth and are at least 500 feet (140 meters) in diameter. These are the objects astronomers want to find and track in order to predict if they pose a risk of colliding with Earth.

There are roughly 2,400 known potentially hazardous asteroids, but there are more lurking out there. Another advantage of using space-based telescopes to search for these asteroids is that they can observe 24 hours a day, while telescopes on the ground are limited to nighttime surveys. Some hazardous asteroids, such as the house-sized object that exploded in the atmosphere over Chelyabinsk, Russia, in 2013, approach Earth from the direction of the Sun. A space telescope has a better chance of finding these kinds of asteroids.

WISE, and then the extended mission of NEOWISE, helped scientists estimate there are approximately 25,000 near-Earth objects.

“The objects (NEOWISE) did discover tended to be overwhelmingly just dark, [and] these are the objects that are much more likely to be missed by the ground-based telescopes,” Mainzer said. “So that, in turn, gives us a much better idea of how many are really out there.”

NASA shuts down asteroid-hunting telescope, but a better one is on the way Read More »

nasa-chief-to-scientists-on-budget-cuts:-“i-feel-your-pain”

NASA chief to scientists on budget cuts: “I feel your pain”

Nelson as Senator Administrator —

“I can’t go and print the dollars.”

Photo of Bill Nelson.

Enlarge / Administrator Bill Nelson delivering remarks and answering questions from the media at the OFT-2 prelaunch press conference.

Trevor Mahlmann

Ars Technica recently had the opportunity to speak with NASA Administrator Bill Nelson, who has now led the US space agency for more than three years. We spoke about budget issues, Artemis Program timelines, and NASA’s role as a soft power in global diplomacy. What follows is a very lightly edited transcript of the conversation between Senior Space Editor Eric Berger and Nelson.

Ars Technica: I wanted to start with NASA’s budget for next year. We’ve now seen the numbers from the House of Senate, and NASA is once again facing some cuts. And I’m just wondering, what are your big concerns as we get into the final budgeting process this fall?

Administrator Bill Nelson: Well, the big concern is that you can’t put 10 pounds of potatoes in a five-pound sack. When you get cut $4.7 billion over two years, and when $2 billion of that over two years is just in science, then you have to start making some hard choices. Now, I understand the reasons for the cuts. Had I still been a member of the Senate I would’ve voted for it simply because they were held hostage by a small group in the House to get what they wanted. Which was reduced appropriations in order to raise the artificial, statutory budget debt ceiling in order for the government not to go into default. That’s part of the legislative process. It’s part of the compromises that go on. It happened over a year ago, and it was called the Fiscal Responsibility Act. The price for doing that wasn’t cuts across the entire budget. Remember, two-thirds of the budget is entitlement programs like Social Security and Medicare, and it certainly wasn’t in defense. So, all the cuts came out of everything left over, including NASA. I’m hoping that we’re going to get a reprieve come fiscal year ’26 when we will not be in the budgetary constraints of the Fiscal Responsibility Act. But who knows? Because lo and behold, they’ve got another artificial debt ceiling they’re going to have to raise next January.

ArsWhat would you say to scientists who are concerned about Chandra, the cancellation of Viper, and Mars Sample Return, who see the budget for Artemis Program holding steady or even going up? It seems to me those of us who lived through Constellation saw this unfolding 15 to 20 years ago. Is the same thing happening with Artemis, is science being cannibalized to pay for human exploration?

Nelson: My response to the scientists is, I feel your pain. But, when I am faced with $2 billion of cuts over two years just in Science, I can’t go and print the dollars. And so, we have to make hard choices. Now, let’s go through those ones that you mentioned. Mars Sample Return. This was getting way out of control. It was going up to $11 billion, and we weren’t even going to get a sample return until 2040. And that’s the decade that when we’re going to land astronauts on Mars. So, something had to be done.

I convinced the budget director, Shalanda Young (director of the US Office of Management and Budget), and she was a partner in this, that we need to get those samples back. And so we pulled the plug on it. We said, “We’re going to start over, and we’re going to go out to all the NASA centers and to private industry, and we’re going to solicit and give some incentive money for their studies. And those studies will come back in, and by the end of the year, we will make a decision.” I’m hopeful that we are going to find such creativity and fiscal discipline that we’re going to end up with a much cheaper Mars sample return that will come back in the mid-30s, instead of all the way to 2040. So, if that’s what happens, and every indication I get is we’re getting some really creative proposals, if that’s what happens, then it’s a win-win. It’s a win for the taxpayer clearly. It’s a win for NASA because we didn’t have the money to spend $11 billion on it.

So, that’s one example. Another one that you used is Viper. Viper was running 40 percent over budget. Now, there comes a limit, and when you have to take a $2 billion hit just to science, you have to make tough choices. And so, that decision was made. We’re still getting (to the Moon) with Intuitive Machines at the end of the year. We are getting a lander that is going to drill to see if there is water underneath the surface. Understand that Viper was a much bigger rover, and it was going to rove around, but it was also 40 percent over budget. And so, these are the choices that you have to make.

You mentioned Chandra. By the way, I think we’ve worked Chandra out. Although it’s not going to have the funding way up there at the top funding. What we have worked out is, we are going to from what we requested, which was $41 million, it’s going to be some amount in excess of that. Although there will be some layoffs, not nearly as many, and all of the science will be protected. There will not be any diminution of the science.

NASA chief to scientists on budget cuts: “I feel your pain” Read More »

i-trust-nasa’s-safety-culture-this-time-around,-and-so-should-you

I trust NASA’s safety culture this time around, and so should you

Through a cloud-washed blue sky above Launch Pad 39A, Space Shuttle <em>Columbia</em> hurtles toward space on mission STS-107. ” src=”https://cdn.arstechnica.net/wp-content/uploads/2016/01/16271647815_f0b8187e11_o-640×474.jpg”></img><figcaption>
<p>Through a cloud-washed blue sky above Launch Pad 39A, Space Shuttle <em>Columbia</em> hurtles toward space on mission STS-107. </p>
<p>NASA</p>
</figcaption></figure>
<p>My first real taste of space journalism came on the morning of February 1, 2003. An editor at the Houston Chronicle telephoned me at home on a Saturday morning and asked me to hurry to Johnson Space Center to help cover the loss of Space Shuttle <em>Columbia</em>.</p>
<p>At the time, I did not realize this tragedy would set the course for the rest of my professional life, that of thinking and writing about spaceflight. This would become the consuming passion of my career.</p>
<p>I’ve naturally been thinking a lot about <em>Columbia</em> in recent weeks. While the parallels between that Space Shuttle mission and the first crewed flight of Boeing’s Starliner spacecraft are not exact, there are similarities. Most significantly, after the Space Shuttle launched, there were questions about the safety of the vehicle’s return home due to foam striking the leading edge of the spacecraft’s wing.</p>
<p>Two decades later, there are many more questions, both in public and private, about the viability of Starliner’s propulsion system after irregularities during the vehicle’s flight to the space station in June. NASA officials made the wrong decision during the <em>Columbia</em> accident. So, facing another <a href=hugely consequential decision now, is there any reason to believe they’ll make the correct call with the lives of Starliner astronauts Butch Wilmore and Suni Williams on the line?

A poor safety culture

To understand Columbia, we need to go back to 1986 and the first Space Shuttle accident involving Challenger. After that catastrophic launch failure, the Rogers Commission investigated and identified the technical cause of the accident while also concluding that it was rooted in a flawed safety culture.

This report prompted sweeping changes in NASA’s culture that were designed to allow lower-level engineers the freedom to raise safety concerns about spaceflight vehicles and be heard. And for a time, this worked. However, by the time of Columbia, when the shuttle had flown many dozens of successful missions, NASA’s culture had reverted to Challenger-like attitudes.

Because foam strikes had been seen during previous shuttle missions without consequence, observations of foam loss from the external tank during Columbia‘s launch were not a significant cause of concern. There were a few dissenting voices who said the issue deserved more analysis. However, the chair of the Mission Management Team overseeing the flight, Linda Ham, blocked a request to obtain imagery of the possibly damaged orbiter from US Department of Defense assets in space. The message from the top was clear: The shuttle was fine to come home.

The loss of Columbia resulted in another investigatory commission, known as the Columbia Accident Investigation Board. One of its members was John Logsdon, an eminent space historian at George Washington University. “We observed that there had been changes after Challenger and that they had gone away, and they didn’t persist,” Logsdon told me in an interview this weekend. “NASA fell back into the pattern that it had been in before Challenger.”

Essentially, then, antibodies within the NASA culture had rebounded to limit dissent.

Advantages for decision-makers today

If it does not precisely repeat itself, history certainly echoes. Two decades after Columbia, Starliner is presently docked to the International Space Station. As with foam strikes, issues with reaction-control system thrusters are not unique to this flight; they were also observed during the previous test flight in 2022. So once again, engineers at NASA are attempting to decide whether they can be comfortable with a “known” issue and all of its implications for a safe return to Earth.

NASA is the customer for this mission rather than the operator—the space agency is buying transportation services to the International Space Station for its astronauts from Boeing. However, as the customer, NASA still has the final say. Boeing engineers will have input, but the final decisions will be made by NASA engineers such as Steve Stich, Ken Bowersox, and Jim Free. Ultimately, NASA Administrator Bill Nelson could have the final say.

I trust NASA’s safety culture this time around, and so should you Read More »

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NASA is about to make its most important safety decision in nearly a generation

Boeing's Starliner spacecraft, seen docked at the International Space Station through the window of a SpaceX Dragon spacecraft.

Enlarge / Boeing’s Starliner spacecraft, seen docked at the International Space Station through the window of a SpaceX Dragon spacecraft.

As soon as this week, NASA officials will make perhaps the agency’s most consequential safety decision in human spaceflight in 21 years.

NASA astronauts Butch Wilmore and Suni Williams are nearly 10 weeks into a test flight that was originally set to last a little more than one week. The two retired US Navy test pilots were the first people to fly into orbit on Boeing’s Starliner spacecraft when it launched on June 5. Now, NASA officials aren’t sure Starliner is safe enough to bring the astronauts home.

Three of the managers at the center of the pending decision, Ken Bowersox and Steve Stich from NASA and Boeing’s LeRoy Cain, either had key roles in the ill-fated final flight of Space Shuttle Columbia in 2003 or felt the consequences of the accident.

At that time, officials misjudged the risk. Seven astronauts died, and the Space Shuttle Columbia was destroyed as it reentered the atmosphere over Texas. Bowersox, Stich, and Cain weren’t the people making the call on the health of Columbia‘s heat shield in 2003, but they had front-row seats to the consequences.

Bowersox was an astronaut on the International Space Station when NASA lost Columbia. He and his crewmates were waiting to hitch a ride home on the next Space Shuttle mission, which was delayed two-and-a-half years in the wake of the Columbia accident. Instead, Bowersox’s crew came back to Earth later that year on a Russian Soyuz capsule. After retiring from the astronaut corps, Bowersox worked at SpaceX and is now the head of NASA’s spaceflight operations directorate.

Stich and Cain were NASA flight directors in 2003, and they remain well-respected in human spaceflight circles. Stich is now the manager of NASA’s commercial crew program, and Cain is now a Boeing employee and chair of the company’s Starliner mission director. For the ongoing Starliner mission, Bowersox, Stich, and Cain are in the decision-making chain.

All three joined NASA in the late 1980s, soon after the Challenger accident. They have seen NASA attempt to reshape its safety culture after both of NASA’s fatal Space Shuttle tragedies. After Challenger, NASA’s astronaut office had a more central role in safety decisions, and the agency made efforts to listen to dissent from engineers. Still, human flaws are inescapable, and NASA’s culture was unable to alleviate them during Columbia‘s last flight in 2003.

NASA knew launching a Space Shuttle in cold weather reduced the safety margin on its solid rocket boosters, which led to the Challenger accident. And shuttle managers knew foam routinely fell off the external fuel tank. In a near-miss, one of these foam fragments hit a shuttle booster but didn’t damage it, just two flights prior to Columbia‘s STS-107 mission.

“I have wondered if some in management roles today that were here when we lost Challenger and Columbia remember that in both of those tragedies, there were those that were not comfortable proceeding,” Milt Heflin, a retired NASA flight director who spent 47 years at the agency, wrote in an email to Ars. “Today, those memories are still around.”

“I suspect Stich and Cain are paying attention to the right stuff,” Heflin wrote.

The question facing NASA’s leadership today? Should the two astronauts return to Earth from the International Space Station in Boeing’s Starliner spacecraft, with its history of thruster failures and helium leaks, or should they come home on a SpaceX Dragon capsule?

Under normal conditions, the first option is the choice everyone at NASA would like to make. It would be least disruptive to operations at the space station and would potentially maintain a clearer future for Boeing’s Starliner program, which NASA would like to become operational for regular crew rotation flights to the station.

But some people at NASA aren’t convinced this is the right call. Engineers still don’t fully understand why five of the Starliner spacecraft’s thrusters overheated and lost power as the capsule approached the space station for docking in June. Four of these five control jets are now back in action with near-normal performance, but managers would like to be sure the same thrusters—and maybe more—won’t fail again as Starliner departs the station and heads for reentry.

NASA is about to make its most important safety decision in nearly a generation Read More »

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China’s Long March 6A rocket is making a mess in low-Earth orbit

Another one —

After nearly every flight, the upper stage of this rocket breaks apart in orbit.

Debris from the upper stage of China's Long March 6A rocket captured from the ground by Slingshot Aerospace.

Enlarge / Debris from the upper stage of China’s Long March 6A rocket captured from the ground by Slingshot Aerospace.

The upper stage from a Chinese rocket that launched a batch of Internet satellites Tuesday has broken apart in space, creating a debris field of at least 700 objects in one of the most heavily-trafficked zones in low-Earth orbit.

US Space Command, which tracks objects in orbit with a network of radars and optical sensors, confirmed the rocket breakup Thursday. Space Command initially said the event created more than 300 pieces of trackable debris. The military’s ground-based radars are capable of tracking objects larger than 10 centimeters (4 inches).

Later Thursday, LeoLabs, a commercial space situational awareness company, said its radars detected at least 700 objects attributed to the Chinese rocket. The number of debris fragments could rise to more than 900, LeoLabs said.

The culprit is the second stage of China’s Long March 6A rocket, which lifted off Tuesday with the first batch of 18 satellites for a planned Chinese megaconstellation that could eventually number thousands of spacecraft. The Long March 6A’s second stage apparently disintegrated after placing its payload of 18 satellites into a polar orbit.

Space Command said in a statement it has “observed no immediate threats” and “continues to conduct routine conjunction assessments to support the safety and sustainability of the space domain.” According to LeoLabs, radar data indicated the rocket broke apart at an altitude of 503 miles (810 kilometers) at approximately 4: 10 pm EDT (20: 10 UTC) on Tuesday, around 13-and-a-half hours after it lifted off from northern China.

At this altitude, it will take decades or centuries for the wispy effect of aerodynamic drag to pull the debris back into the atmosphere. As the objects drift lower, their orbits will cross paths with SpaceX’s Starlink Internet satellites, the International Space Station and other crew spacecraft, and thousands more pieces of orbital debris, putting commercial and government satellites at risk of collision.

A new debris field of nearly 1,000 objects would be a significant addition to the approximately 46,000 objects Space Command tracks in Earth orbit. According to statistics compiled by Jonathan McDowell, an astrophysicist who monitors global launch and spaceflight activity, this would rank in the top five of all debris-generation events since the dawn of the Space Age.

This rocket has a track record

The medium-class Long March 6A rocket has launched seven times since debuting in March 2022, and military and commercial satellite tracking organizations have reported several breakups of the rocket’s upper stage. In November 2022, a Long March 6A upper stage disintegrated in orbit, creating a debris field of more than 500 trackable objects, according to NASA’s Orbital Debris Program Office.

Commercial satellite tracking companies observed smaller debris fields following several other Long March 6A flights this year.

In its space environment statistics report, the European Space Agency says there have been more than 640 “breakups, explosions, collisions, or anomalous events resulting in fragmentation” in orbit. So these things happen frequently. But it’s not clear what makes the Long March 6A, which has a relatively short flight history, particularly vulnerable to creating debris.

A Long March 6A rocket launches the first 18 Internet satellites for China's Qianfan, or Thousand Sails, broadband network.

Enlarge / A Long March 6A rocket launches the first 18 Internet satellites for China’s Qianfan, or Thousand Sails, broadband network.

Most rockets operating today either reignite their engines to reenter the atmosphere after deploying their payloads, or if that’s not feasible, they “passivate” themselves to empty their propellant tanks and drain their batteries to reduce the risk of an explosion.

In a report last year, NASA’s Orbital Debris Program Office said the Long March 6A upper stage has a mass of about 5,800 kilograms (12,800 pounds) without kerosene and liquid oxygen propellants. It is powered by a single YF-115 engine.

The launch Tuesday began the deployment of China’s “Thousand Sails” Internet network, which will initially consist of 1,296 satellites, with the possibility to expand to more than 14,000 spacecraft. This will require numerous launches, some of which will presumably use the Long March 6A.

“If even a fraction of the launches needed to field this Chinese megaconstellation generate as much debris as this first launch, the result would be a notable addition to the space debris population in LEO (low-Earth orbit),” said Audrey Schaffer, vice president of strategy and policy at Slingshot Aerospace, a commercial satellite tracking and analytics firm.

China has been responsible for several space debris incidents beyond the latest problems with the Long March 6A rocket. In 2007, China destroyed one of its own spacecraft in an anti-satellite missile test. This was the worst-ever instance of creating space debris, resulting in more than 3,000 trackable objects, and an estimate 150,000 or more smaller fragments.

On four occasions from 2020 through 2022, the massive core stage of China’s heavy-lift Long March 5B rocket has reentered the atmosphere in an uncontrolled manner, raising concerns that falling debris could put people and property at risk on Earth.

China plans more flights with its Long March 5B and Long March 6A rockets. China continued flying the Long March 5B rocket despite the risk it posed to people on the ground. Debris fields in orbit, however, don’t directly threaten any people on Earth, but they do raise the risk to satellites of all nations, including China’s own spacecraft.

“Events like this highlight the importance of adherence to existing space debris mitigation guidelines to reduce the creation of new space debris and underscore the need for robust space domain awareness capabilities to rapidly detect, track, and catalog newly-launched space objects so they can be screened for potential conjunctions,” Schaffer said in a statement.

This story was updated with the detection of additional debris fragments by LeoLabs.

China’s Long March 6A rocket is making a mess in low-Earth orbit Read More »

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Rocket Report: Archimedes engine sees first light, New Glenn making moves

All the news that’s fit to lift —

“Coming soon: a full recovery rehearsal with our landing vessel.”

Rocket Lab says it fired up the Archimedes engine at full thrust this week.

Enlarge / Rocket Lab says it fired up the Archimedes engine at full thrust this week.

Rocket Lab

Welcome to Edition 7.06 of the Rocket Report! There has been a lot of drama over the last week involving NASA, the crew of Starliner on board the International Space Station, and the launch of the Crew-9 mission on a Falcon 9 rocket. NASA is now down to a binary choice: Fly Butch Wilmore and Suni Williams home on Starliner, or send two astronauts to orbit on Crew-9, and return Wilmore and Williams next February on that spacecraft. We should know NASA’s final decision next week.

As always, we welcome reader submissions, and if you don’t want to miss an issue, please subscribe using the box below (the form will not appear on AMP-enabled versions of the site). Each report will include information on small-, medium-, and heavy-lift rockets as well as a quick look ahead at the next three launches on the calendar.

Firefly inks another big Alpha contract. Firefly Aerospace said Wednesday that it has signed a multi-launch agreement with L3Harris Technologies for up to 20 launches on Firefly’s Alpha rocket, including two to four missions per year from 2027 to 2031, depending on customer needs. The new agreement is in addition to Firefly’s existing multi-launch agreement with L3Harris for three Alpha missions in 2026. What is not clear is exactly what satellites L3Harris wants to launch.

Putting skins on the wall … “Firefly continues to see growing demand for Alpha’s responsive small-lift services, and we’re committed to providing a dedicated launch option that takes our customers directly to their preferred orbits,” said Peter Schumacher, Interim CEO at Firefly Aerospace. This represents another significant win for the Alpha rocket, which can lift about 1 metric ton to low-Earth orbit. Under terms of a separate agreement announced in June, Lockheed purchased 15 launches from Firefly, with an option for 10 more, through the year 2029. (submitted by Ken the Bin and EllPeaTea)

Electron pushing launch cadence. Rocket Lab announced Wednesday that it has scheduled the launch for its 52nd Electron mission, which will deploy a single satellite for American space tech company Capella Space. The mission is scheduled to launch during a 14-day window that opens on August 11 from Rocket Lab Launch Complex 1 on New Zealand’s Mahia Peninsula.

Getting to ten much faster … Should this launch take place at the opening of this window, this Electron flight would occur just eight days after the most recent Electron mission on August 3. This upcoming mission for Capella will be Rocket Lab’s tenth mission for 2024, equaling the company’s annual launch record set in 2023. (submitted by Ken the Bin)

The easiest way to keep up with Eric Berger’s space reporting is to sign up for his newsletter, we’ll collect his stories in your inbox.

PLD Space to start work on launch site. PLD Space plans to start building launch facilities for its Miura 5 rocket in October from the Diamant site at Guiana Space Centre, cofounder and Chief Business Development Officer Raúl Verdú said this week, Space News reports. Diamant has been dormant for decades after once being used for the French rocket of the same name, and “in the area where we are there is nothing,” Verdú said, “we have to do everything from scratch.”

Lots of things to build … PLD Space, Germany’s Isar Aerospace and a handful of other small European launchers are working with France’s CNES space agency to convert the site into a multi-use facility. In June, the Spanish company announced a 10 million euro ($11 million) investment plan for 15,765 square meters of space at Diamant, divided between a launch zone and a preparation area comprising an integration hangar, clean room, control center, commercial and work offices. CNES is providing common infrastructure such as roads and electricity networks. (submitted by Ken the Bin)

Japanese firm raises $21 million. Interstellar Technologies announced a new fundraising round that brings its total capital and government funding to $117 million, Payload reports. After building and launching a suborbital rocket called Momo, the company is building its first orbital rocket, dubbed ZERO, with a goal of flying in 2025. This rocket is intended to carry 800 kg of payload to low-Earth orbit, and be cheaper than Rocket Lab’s Electron, COO Keiji Atsuta said.

Big help from Japan … Interstellar’s latest round was led by Japanese VC fund SBI and NTT Docomo, the country’s leading mobile firm. Previously, it received a large amount of funding, $96 million, from the Japanese government. “The Japanese government has explicitly expressed its support for private rockets due to the growing importance of the space industry, and being selected for this support program has significantly accelerated our business,” Interstellar CEO Takahiro Inagawa said. (submitted by Ken the Bin)

Cross-border deal benefits Nova Scotia spaceport. The Canadian government says it has completed negotiations with the United States on an agreement that would allow the use of US space launch technology, expertise, and data for space launches in Canada, the AP reports. Maritime Launch Services, the company developing Canada’s first commercial spaceport in northeastern Nova Scotia, called the agreement a major step forward for the industry.

US rockets could launch from Canada … Ottawa has said it hopes to position Canada as future leader in commercial space launches. The country has geographical advantages, including a vast, sparsely populated territory and high-inclination orbits. The agreement, which is yet to be signed, will establish the legal and technical safeguards needed while ensuring the proper handling of sensitive technology, the government said in a news release. (submitted by JoeyS-IVB)

Rocket Report: Archimedes engine sees first light, New Glenn making moves Read More »

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“Archeology” on the ISS helps identify what astronauts really need

Archeology without the dig —

Regular photography shows a tool shed and more isolated toilet would be appreciated.

I woman holds a handheld device in front of a rack of equipment.

Enlarge / Jessica Watkins gets to work on the ISS

“Archeology really is a perspective on material culture we use as evidence to understand how humans adapt to their environment, to the situations they are in, and to each other. There is no place, no time that is out of bounds,” says Justin Walsh, an archeologist at Chapman University who led the first off-world archeological study on board the ISS.

Walsh’s and his team wanted to understand, document, and preserve the heritage of the astronaut culture at one of the first permanent space habitats. “There is this notion about astronauts that they are high achievers, highly intelligent, and highly trained, that they are not like you and me. What we learned is that they are just people, and they want the comforts of home,” Walsh says.

Disposable cameras and garbage

“In 2008, my student in an archeology class raised her hand and said, ‘What about stuff in space, is that heritage?’ I said, ‘Oh my God, I’ve never thought of this before, but yes,’” Walsh says. “Think of Tranquility base—it’s an archeological site. You could go back there, and you could reconstruct not only the specific activities of Neil Armstrong and Buzz Aldrin, but you could understand the engineering culture, the political culture, etc. of the society that created that equipment, sent it to the Moon, and left it there.”

So he conceived the idea of an archeological study on the ISS, wrote a proposal, sent it to NASA, and got rejected. NASA said human sciences were not their priority and not part of their mission. But in 2021, NASA changed its mind.

“They said they had an experiment that could not be done at the scheduled time, so they had to delay it. Also, they changed the crew size from six to seven people,” says Walsh. These opened up some idle time in the astronauts’ schedules, allowing NASA to find space in the schedule for less urgent projects on the station. The agency gave Walsh’s team the go-ahead under the condition that their study could be done with the equipment already present on the ISS.

The outline of Walsh’s research was inspired by and loosely based on the Tucson Garbage Project and the Undocumented Migration Project, two contemporary archeology studies. The first drew conclusions about people’s lives by studying the garbage they threw away. The second documented the experiences of migrants on their way to the US from Mexico.

“Jason De León, who is the principal investigator of this project, gave people in Mexico disposable cameras, and he retrieved those cameras from them when they got to the US. He could observe things they experienced without being there himself. For me, that was a lightbulb moment,” says Walsh.

There were cameras on board the ISS and there was a crew to take pictures with them. To pull off an equivalent of digging a test pit in space, Walsh’s team chose six locations on the station, asked the crew to mark them with squares one meter across, and asked the astronauts to take a picture of each of those squares once a day for 60 days, from January to March 2022.

Building a space shed

In the first paper discussing the study’s results, Walsh’s team covered two out of six chosen locations, dubbed squares 03 and 05. The 03 square was in a maintenance area near the four crew berths where the US crew sleeps. It’s near docking ports for spacecraft coming to the ISS. The square was drawn around a blue board with Velcro patches meant to hold tools and equipment in place.

“All historic photographs of this location published by NASA show somebody working in there—fixing a piece of equipment, doing a science experiment,” says Walsh. But when his team analyzed day-by-day photos of the same spot, the items velcroed to the wall hardly changed in those 60 days. “It was the same set of items over and over again. If there was an activity, it was a scientific experiment. It was supposed to be the maintenance area. So where was the maintenance? And even if it was a science area, where’s the science? It was only happening on 10 percent of days,” Walsh says.

“Archeology” on the ISS helps identify what astronauts really need Read More »

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A new report finds Boeing’s rockets are built with an unqualified work force

$L$ —

NASA declines to penalize Boeing for the deficiencies.

EUS panel test weld at the Michoud Assembly Facility on Tuesday, February 9, 2021.

Enlarge / EUS panel test weld at the Michoud Assembly Facility on Tuesday, February 9, 2021.

Michael DeMocker/NASA

The NASA program to develop a new upper stage for the Space Launch System rocket is seven years behind schedule and significantly over budget, a new report from the space agency’s inspector general finds. However, beyond these headline numbers, there is also some eye-opening information about the project’s prime contractor, Boeing, and its poor quality control practices.

The new Exploration Upper Stage, a more powerful second stage for the SLS rocket that made its debut in late 2022, is viewed by NASA as a key piece of its Artemis program to return humans to the Moon. The current plan calls for the use of this new upper stage beginning with the second lunar landing, the Artemis IV mission, currently scheduled for 2028. In NASA parlance, the upgraded version of the SLS rocket is known as Block 1B.

However, for many reasons—including the readiness of lunar landers, Lunar Gateway hardware, a new mobile launch tower, and more—NASA is unlikely to hold that date. Now, based on information in this new report, we can probably add the Exploration Upper Stage to the list.

“We found an array of issues that could hinder SLS Block 1B’s readiness for Artemis IV including Boeing’s inadequate quality management system, escalating costs and schedules, and inadequate visibility into the Block 1B’s projected costs,” states the report, signed by NASA’s deputy inspector general, George A. Scott.

Quality control a concern

There are some surprising details in the report about Boeing’s quality control practices at the Michoud Assembly Facility in southern Louisiana, where the Exploration Upper Stage is being manufactured. Federal observers have issued a striking number of “Corrective Action Requests” to Boeing.

“According to Safety and Mission Assurance officials at NASA and DCMA officials at Michoud, Boeing’s quality control issues are largely caused by its workforce having insufficient aerospace production experience,” the report states. “The lack of a trained and qualified workforce increases the risk that the contractor will continue to manufacture parts and components that do not adhere to NASA requirements and industry standards.”

This lack of a qualified workforce has resulted in significant program delays and increased costs. According to the new report, “unsatisfactory” welding operations resulted in propellant tanks that did not meet specifications, which directly led to a seven-month delay in the program.

NASA’s inspector general was concerned enough with quality control to recommend that the space agency institute financial penalties for Boeing’s noncompliance. However, in a response to the report, NASA’s deputy associate administrator, Catherine Koerner, declined to do so. “NASA interprets this recommendation to be directing NASA to institute penalties outside the bounds of the contract,” she replied. “There are already authorities in the contract, such as award fee provisions, which enable financial ramifications for noncompliance with quality control standards.”

The lack of enthusiasm by NASA to penalize Boeing for these issues will not help the perception that the agency treats some of its contractors with kid gloves.

Seven years late

The new report predicts that Block 1B development costs will reach $5.7 billion before it ultimately launches, which is already $700 million more than a cost estimate NASA formally established just last December.

As for the upper stage itself, NASA initially predicted development costs would be $962 million back in 2017. However, the new report predicts that the Exploration Upper Stage will actually cost $2.8 billion, or three times the original cost estimate. (For what it is worth, Ars used a simple estimating tool in 2019 to predict the Exploration Upper Stage development cost would be $2.5 billion. So it’s not like it was a huge secret that NASA and Boeing would blow out the budget here).

The delays in Exploration Upper Stage development are almost year for year.

Enlarge / The delays in Exploration Upper Stage development are almost year for year.

NASA Inspector General

However, the increased costs will benefit Boeing, since this is a cost-plus contract that pays for all of Boeing’s expenses, plus a fee. This may help explain why a development program that was originally supposed to be completed in 2021 is not likely to be finished until 2028 at the earliest.

And what for? The Space Launch System works great as it is. There are far, far cheaper upper stages that could be used for the rocket’s primary function to launch the Orion spacecraft to lunar orbit, including United Launch Alliance’s reliable (and ready) Centaur V upper stage. With Starship and New Glenn, NASA will also soon have two very powerful commercial super heavy lift rockets to draw upon.

A new report finds Boeing’s rockets are built with an unqualified work force Read More »