NASA Continues Slow And Steady Pace Towards Moon

March 28, 2022 by Tom Nardi 61 Comments

It’s often said that the wheels of government turn slowly, and perhaps nowhere is this on better display than at NASA. While it seems like every week we hear about another commercial space launch or venture, projects helmed by the national space agency are often mired by budget cuts and indecisiveness from above. It takes a lot of political will to earmark tens or even hundreds of billions of dollars on a project that could take decades to complete, and not every occupant of the White House has been willing to stake their reputation on such bold ambitions.

In 2019, when Vice President Mike Pence told a cheering crowd at the U.S. Space & Rocket Center that the White House was officially tasking NASA with returning American astronauts to the surface of the Moon by 2024, everyone knew it was an ambitious timeline. But not one without precedent. The speech was a not-so-subtle allusion to President Kennedy’s famous 1962 declaration at Rice University that America would safely land a man on the Moon before the end of the decade, a challenge NASA was able to meet with fewer than six months to spare.

Unfortunately, a rousing speech will only get you so far. Without a significant boost to the agency’s budget, progress on the new Artemis lunar program was limited. To further complicate matters, less than a year after Pence took the stage in Huntsville, there was a new President in the White House. While there was initially some concern that the Biden administration would axe the Artemis program as part of a general “house cleaning”, it was allowed to continue under newly installed NASA Administrator Bill Nelson. The original 2024 deadline, at this point all but unattainable due to delays stemming from the COVID-19 pandemic, has quietly been abandoned.

So where are we now? Is NASA in 2022 any closer to returning humanity to the Moon than they were in 2020 or even 2010? While it might not seem like it from an outsider’s perspective, a close look at some of the recent Artemis program milestones and developments show that the agency is at least moving in the right direction.

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Astra’s Frugal Design Leads To Latest Unusual Failure

February 23, 2022 by Tom Nardi 36 Comments

We’ve all heard it said, and it bears repeating: getting to space is hard. But it actually gets even harder the smaller your booster is. That’s because the structure, engines, avionics, and useful payload of a rocket only make up a tiny portion of its liftoff mass, while the rest is dedicated to the propellant it must expend to reach orbital velocity. That’s why a Falcon 9 tipping the scales at 549,054 kilograms (1,207,920 pounds) can only loft a payload of 22,800 kg (50,265 lb) — roughly 4% of its takeoff weight.

As you might imagine, there’s a lower limit where there simply isn’t enough mass in the equation for the hardware necessary to build a fully functional rocket. But where is that limit? That’s precisely what aerospace newcomer Astra is trying to find out. Their Rocket 3 is among the smallest orbital boosters to ever fly, closer in size and mass to the German V2 of World War II than the towering vehicles being built by SpaceX or Blue Origin. Even the Rocket Lab Electron, itself an exceptionally svelte rocket, is considerably larger.

The reason they’re trying to build such a small rocket is of course very simple: smaller means cheaper. Assuming you’ve got a payload light and compact enough to fit on their launcher, Astra says they can put it into orbit for roughly $2.5 million USD; less than half the cost of a dedicated flight aboard Rocket Lab’s Electron, and competitive with SpaceX’s “rideshare” program. Such a low ticket price would have been unfathomable a decade ago, and promises to shake up an already highly competitive commercial launch market. But naturally, Astra has to get the thing flying reliably before we can celebrate this new spaceflight milestone.

Their latest mission ended in a total loss of the vehicle and payload when the upper stage tumbled out of control roughly three minutes after an otherwise perfect liftoff from Cape Canaveral Space Force Station in Florida. Such issues aren’t uncommon for a new orbital booster, and few rockets in history have entered regular service without a lost payload or two on the books. But this failure, broadcast live over the Internet, was something quite unusual: because of the unconventional design of Astra’s diminutive rocket, the upper stage appeared to get stuck inside the booster after the payload fairing failed to open fully.

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Blue Origin Rolls Out Test Article For Next-Gen Rocket

November 22, 2021 by Tom Nardi 28 Comments

By any metric you care to use, this is a very exciting time for America’s space program. NASA is refocusing their efforts towards the Moon and beyond, SpaceX is launching routine crew and cargo flights to the International Space Station with reusable rockets, and if you’ve got deep enough pockets, there are now multiple companies offering suborbital pleasure trips requiring little more than a few hours worth of training. It’s taken longer than many people had hoped, but it seems we’re finally making the confident strides necessary to truly utilize space’s vast resources.

But things are just getting started. A new generation of massive reusable rockets are currently being developed, which promise to make access to space cheaper and faster than ever before. We’ve seen quite a bit of SpaceX’s Starship, thanks in no small part to the dramatic test flights that the media-savvy company has been regularly live streaming to YouTube. But Blue Origin, founded by Amazon’s Jeff Bezos, has been far more secretive about their New Glenn. That is, until now.

On November 8th, Blue Origin rolled out their GS1 simulator for the New Glenn’s first stage. This stand-in for the real rocket will never fly, but it’s designed to perfectly recreate the dimensions, center of gravity, and mass, of the real thing. Ground teams will use the GS1 to practice safely transporting the booster, which is approximately half the length of the Saturn V, from their production facility to Launch Complex 36 (LC-36) at Cape Canaveral. It will also be used to test the fit and function of various pieces of ground support equipment, and eventually, the second stage stacking procedure.

For the uninitiated, it might seem like this is a lot of fuss over what’s ultimately just a hollow metal tube. But the introduction of a test article such as this has traditionally been a major milestone during the design and construction of rockets and spacecraft, dating back to the “boilerplate” test capsules used during the Mercury, Gemini, and Apollo programs; a sure sign that what was just an idea is now becoming a reality.

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StarLink Terminal Unit Firmware Dumped

July 7, 2021 by Al Williams 17 Comments

There’s a lot of expense in what telephone companies call “the last mile” — delivering service from the main trunks to your home or business. StarLink wants to avoid that cost by connecting you via an array of low-orbit satellites and some users are already using the service. In Belgium, [Lennert Wouters] managed to dump the terminal’s firmware and has some interesting observations.

The teardown is actually more than just a firmware dump. His “level 1” teardown involves exposing the board. This can be tricky because there are apparently different versions of the terminal out already, so advice from one source might not match your hardware, and that was the case here.

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Not All SpaceX Software Goes To Space

June 1, 2021 by Roger Cheng 13 Comments

SpaceX has always been willing to break from aerospace tradition if they feel there’s a more pragmatic solution. Today this is most visible in their use of standard construction equipment like cranes in their Starship development facility. But the same focus on problem solving can also be found in their software parts we don’t see. Recently we got two different views behind the scenes. First, a four-part series about “software in space” published by StackOverflow blog, followed quickly by an Ask Me Anything (AMA) session on SpaceX Reddit.

Some of the StackOverflow series cover ground that has been previously discussed. Mostly in the first part dealing with their workhorse Falcon and Dragon vehicles, and some in the second part discussing Starlink whose beta program is reaching more and more people. Both confirmed that spaceflight software has to meet very stringent requirements and are mostly close to the metal bespoke C++ code. But we receive fascinating new information in part three, which focuses on code verification and testing. Here they leverage a lot of open source infrastructure more common to software startups than aerospace companies. The fourth and final component of this series covers software to support SpaceX hardware manufacturing, which had been rarely discussed before this point. (Unfortunately, there was nothing about how often SpaceX software developers copy and paste code from StackOverflow.)

The recent Reddit AMA likewise had some overlap with the SpaceX software AMA a year ago, but there were new information about SpaceX work within the past year. There was Crew Dragon’s transition from a test to an operational vehicle, and the aforementioned Starship development program. Our comments section had a lot of discussion about the practicality of touchscreen interfaces in real spacecraft, and here we learn SpaceX put a lot of study into building something functional and effective.

It also showed us that essentially every Sci-Fi Movie Interface was unrealistic and would be unreadable under extreme conditions.

In the course of this research, they learned a lot of pitfalls about fictional touch interfaces. Though to be fair, movie and television spacecraft UI are more concerned about looking cool than being useful.

If the standard AMA format is not to your liking, one of the contributors compiled all SpaceX answers alongside their related questions in a much more readable form here. And even though there’s an obvious recruiting side to these events, we’re happy to learn more about how SpaceX have continued to focus on getting the job done instead of rigidly conforming to aerospace tradition. An attitude that goes all the way back to the beginning of this company.

SpaceX Drops The Ball On Catching Fairings

May 6, 2021 by Tom Nardi 91 Comments

You don’t have to look very hard to find another rousing success by SpaceX. It’s a company defined by big and bold moves, and when something goes right, they make sure you know about it. From launching a Tesla into deep space to the captivating test flights of their next-generation Starship spacecraft, the private company has turned high-stakes aerospace research and development into a public event. A cult of personality has developed around SpaceX’s outlandish CEO Elon Musk, and so long as he’s at the helm, we can expect bigger and brighter spectacles as he directs the company towards its ultimate goal of putting humans on Mars.

Of course, things don’t always go right for SpaceX. While setbacks are inevitable in aerospace, the company has had a few particularly embarrassing failures that could be directly attributed to their rapid development pace or even operational inexperience. A perfect example is the loss of the Israeli AMOS-6 satellite during a static fire of the Falcon 9’s engines on the launch pad in 2016, as industry experts questioned why the spacecraft had even been mounted to the rocket before it had passed its pre-flight checks. Since that costly mistake, the company has waited until all engine tests have been completed before attaching the customer’s payload.

SpaceX’s concept art for propulsive landing

But sometimes the failure isn’t so much a technical problem as an inability for the company to achieve their own lofty goals. Occasionally one of Musk’s grand ideas ends up being too complex, dangerous, or expensive to put into practice. For instance, despite spending several years and untold amounts of money perfecting the technology involved, propulsive landings for the Crew Dragon were nixed before the idea could ever fully be tested. NASA was reportedly uncomfortable with what they saw as an unnecessary risk compared to the more traditional ocean splashdown under parachutes; it would have been an impressive sight to be sure, but it didn’t offer a substantive benefit over the simpler approach.

A similar fate recently befell SpaceX’s twin fairing recovery ships Ms. Tree and Ms. Chief, which were quietly retired in April. These vessels were designed to catch the Falcon’s school bus sized payload fairings as they drifted down back to Earth using massive nets suspended over their decks, but in the end, the process turned out to be more difficult than expected. More importantly, it apparently wasn’t even necessary in the first place.

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Crew Dragon’s Short Hop Begins The Era Of Valet Parking At The ISS

April 15, 2021 by Tom Nardi 19 Comments

They weren’t scheduled to return to Earth until April 28th at the earliest, so why did NASA astronauts Michael Hopkins, Victor Glover, and Shannon Walker, along with Japan Aerospace Exploration Agency (JAXA) astronaut Soichi Noguchi, suit up and climb aboard the Crew Dragon Resilience on April 5th? Because a previously untested maneuver meant that after they closed the hatch between their spacecraft and the International Space Station, there was a chance they weren’t going to be coming back.

On paper, moving a capsule between docking ports seems simple enough. All Resilience had to do was undock from the International Docking Adapter 2 (IDA-2) located on the front of the Harmony module, itself attached to the Pressurized Mating Adapter 2 (PMA-2) that was once the orbital parking spot for the Space Shuttle, and move over to the PMA-3/IDA-3 on top of Harmony. It was a short trip through open space, and when the crew exited their craft and reentered the Station at the end of it, they’d only be a few meters from where they started out approximately 45 minutes prior.

The maneuver was designed to be performed autonomously, so technically the crew didn’t need to be on Resilience when it switched docking ports. But allowing the astronauts to stay aboard the station while their only ride home undocked and flew away without them was a risk NASA wasn’t willing to take.

What if the vehicle had some issue that prevented it from returning to the ISS? A relocation of this type had never been attempted by an American spacecraft before, much less a commercial one like the Crew Dragon. So while the chances of such a mishap were slim, the crew still treated this short flight as if it could be their last day in space. Should the need arise, all of the necessary checks and preparations had been made so that the vehicle could safely bring its occupants back to Earth.

Thankfully, that wasn’t necessary. The autonomous relocation of Crew Dragon Resilience went off without a hitch, and SpaceX got to add yet another “first” to their ever growing list of accomplishments in space. But this first relocation of an American spacecraft at the ISS certainly won’t be the last, as the comings and goings of commercial spacecraft will only get more complex in the future.

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