Sierra Space has officially commenced the final testing and launch preparations for its innovative Dream Chaser spaceplane and the accompanying Shooting Star cargo module at NASA’s Kennedy Space Center in Florida.
This marks a significant milestone ahead of the company’s inaugural mission to resupply the International Space Station (ISS). Additionally, Sierra Space has secured an agreement with All Points Logistics for the reprocessing of the reusable spaceplane onsite in Florida for future missions.
Sierra Space has over 30 years of experience and 500 missions under its belt, the company aims to transform space transportation with the Dream Chaser and pioneering new space destination technologies with its inflatable and expandable space stations.
The company also offers orbital services to commercial, Department of Defense (DoD), and national security organizations, expanding production to support constellation projects and developing a range of systems and subsystems.
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Finally in Florida
The Dream Chaser and the Shooting Star module arrived at the Kennedy Space Center just before Memorial Day and are now undergoing final assembly, testing, and pre-launch processing at the Space Systems Processing Facility (SSPF). This facility is historically significant, having staged all components of the ISS.
In recent weeks, Sierra Space and NASA teams have prepared for the upcoming tasks, including environmental testing, closeout checks on propulsion and electrical systems, the application of remaining thermal protection tiles, and pre-launch processing for Dream Chaser’s rocket launch.
Tom Vice, CEO of Sierra Space, emphasized the importance of this milestone: “We are on the cusp of achieving a major milestone for Sierra Space and the commercial space industry.”
“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,” Vice added in a statement.
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Next steps toward launch
The launch preparation process encompasses three primary areas:
- Final Assembly and System Checks: this includes the installation of the remaining thermal protection system tiles and propulsion system closeout and leak testing.
- Continued Environmental Testing: upcoming tests will include Electromagnetic Interference (EMI) and Electromagnetic Compatibility (EMC) testing, ensuring all electrical components function seamlessly in space’s challenging radio frequency (RF ) environment. Acoustic testing will verify the spacecraft’s ability to withstand the intense noise levels during launch, and runway testing will ensure Dream Chaser’s differential braking system functions properly upon returning from space.
- Pre-Launch Processing: this final stage involves encapsulating the spacecraft in the rocket fairing and integrating it with the ULA Vulcan Centaur’s systems.
The Dream Chaser transportation system, featuring cargo delivery and return capability, and delivery and disposal capability with the Shooting Star module, introduces a new dimension to NASA’s Commercial Resupply Services missions.
Dream Chaser’s winged design allows it to land on a runway, making it 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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Long-term operations
As Sierra Space nears regular mission operations, the company is preparing for ground reprocessing operations of the reusable Dream Chaser spaceplane in Florida, to ensure efficient mission turnaround.
The company has partnered with All Points Logistics for long-term ground processing of the Dream Chaser fleet from 2026 onwards. The All Points’ planned Space Prep facility complex near the Kennedy Space Center runway will support this effort.
“All Points is excited to be a part of the Sierra Space team. Our Kennedy Space Center Complex will provide the flexibility needed to support a diverse range of future Dream Chaser missions,” said Phil Monkress, CEO of All Points Logistics.
Upon landing, the Dream Chaser will be transported to the planned Space Prep facility for inspection, offloading, and preparation for subsequent missions. The Space Prep complex will feature approximately 500,000 square feet of state-of-the-art infrastructure to support spacecraft operations seamlessly from the factory to the launch pad.
This comprehensive approach consolidates ground infrastructure and operations such as turnkey propellant servicing, payload integration and servicing, equipment storage, and dedicated control centers in a single complex.
The unique design features dual processing spaces to eliminate processing chokepoints and incorporates advanced technology to avoid facility evacuations during hazardous operations, ensuring efficient Dream Chaser flight preparations.
