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Dream Chaser

Sierra Space's Dream Chaser is a reusable reentry vehicle capable of carrying payloads to and from low Earth orbit. The National Aeronautics and Space Administration has contracted with Sierra Space to deliver supplies to the International Space Station under the Commercial Resupply Services 2 (CRS-2) contract. The Dream Chaser vehicle would be launched as payload on a United Launch Alliance Atlas V at a different site.

Dream Chaser has a cross-range capability of ±700 nautical miles (nmi), meaning the ground track of the current vehicle orbit can be up to 700 nmi away when perpendicular to the landing site for Dream Chaser to have enough energy to successfully land. Only ascending trajectories would be considered.9 The specific trajectory Dream Chaser would fly would be a function of where the Dream Chaser is relative to the landing site at the time of departure from orbit. This can be calculated in advance of a reentry as it is based on the orbital mechanics (physics) of the orbit relative to the Earth.

The Dream Chaser is a revival of NASA's HL-20 Personnel Launch System lifting-body design. The Dream Chaser Space System is designed to be optionally piloted and transport up to seven crew members and cargo to LEO destinations with a gentle return to a runway landing. The Dream Chaser spacecraft is 30 feet, or 9 meters, long which is roughly ¼ the total length of the Space Shuttle orbiters. The spacecraft can carry the same crew size as the Space Shuttle and can remain docked to the ISS considerably longer.

Sierra Space’s Dream Chaser is a multi-mission space utility vehicle designed to transport cargo to low Earth orbit (LEO) destinations such as the ISS. NASA purchases these missions to provide a commercial resupply service, thus allowing the vehicle to be used to support additional missions for other government and non-government customers. The Dream Chaser is a lifting-body spacecraft with small wings that provide directional stability in flight. The lifting-body design gives Dream Chaser an efficient lift-to-drag ratio and allows for enhanced cross-range landing capability.

Dream Chaser measures approximately 30 feet in length, has a wingspan of 27 feet, and weighs approximately 24,600 pounds. Dream Chaser propellants, Hydrogen Peroxide (H2O2) and Kerosene (RP1), are used by a Reaction Control System (RCS) for orbital maneuvers, deorbit burn, and high-altitude attitude control during reentry. The propulsion system is not used near or on the ground. Near Mach 4, Dream Chaser transitions from RCS attitude control to flight control surfaces. The vehicle lands with residual propellant and any margin not used during reentry. The pressurized/unpressurized cargo capacity is 5,500 kilograms or 30 cubic feet. The return payload capacity is 1,850 kilograms. During reentry, Dream Chaser would release the cargo module. Unwanted cargo and the cargo module are expected to burn up upon reentry into Earth’s atmosphere. Any surviving debris fragments would be small and land in a remote part of the Pacific Ocean away from major commercial shipping lanes.

Typical cargo includes scientific experiments, items no longer needed on the ISS packaged in cargo transfer bags, and trash for disposal in the cargo module. Overall, for the CRS2 missions, NASA provides Sierra Space and thus the FAA an integrated bag level hazard analysis (IBLHA). The IBLHA assesses any hazards present in the proposed cargo manifest. Sierra Space does not expect any hazardous material as defined by the FAA to be manifested on a reentry. Per NASA’s payload process for CRS2 missions, the cargo for each mission is provided to Sierra Space, and thus the FAA, at the integrated bag level 60 days prior to reentry. The cargo module is constructed of metallic materials (Aluminum, Steel, and Titanium), as well as Sierra Space proprietary composites.

The initial focus of the SpaceDev Advanced Systems group is an overall space transportation system based on the NASA HL-20 lifting body spaceplane. Christened the Dream ChaserTM, it is being designed to carry passengers and cargo in the sub-orbital and orbital flights regimes, including flights to and from the International Space Station. Leveraging the work performed on the NASA HL-20, the Dream ChaserTM will provide a safe and affordable solution for commercial space operations, will launch vertically and land horizontally on conventional runways.

As of December 31, 2006, SpaceDev's executive officers and directors together beneficially owned approximately 45.7% of the issued and outstanding shares of our common stock. James W. Benson and Susan C. Benson beneficially own approximately 22% of SpaceDev common stock. Mr. Benson separated from SpaceDev's employ in September 2006 and founded Benson Space Company but retains a seat on our Board of Directors. In October 2006, SpaceDev was awarded a $330,000 Phase I study contract from Benson Space Company to further the SpaceDev Dream ChaserT spaceship program. The study contributed to the on-going development of the spaceship and resulted in space vehicle and rocket motor designs ready for Phase II vehicle fabrication and testing. The SpaceDev Dream ChaserT spaceship is based on NASA's design of the ten passenger orbital HL-20 Personnel Launch System, and will launch vertically and land horizontally. SpaceDev recognized approximately $76,000 in revenue under this contract from inception through December 31, 2006.

SpaceDev is currently working in conjunction with NASA Commercial Orbital Transporation Services (COTS) office to develop and configure the system for ISS servicing. In parallel, SpaceDev has signed a memorandum of understanding with United Launch Alliance (ULA) and is evaluating man-rating the Atlas 5 launch vehicle and configuring it for use with Dream ChaserTM to provide a launch configuration based on the exceptional heritage of the Atlas family of launch vehicles.

Marketing and sales expenses increased to approximately $2.2 million, or 6.8% of net sales, for the year ended December 31, 2006, from approximately $674,000, or 7.5% of net sales, during the same period in 2005. The total dollar increase of approximately $1.5 million was mainly due to costs related to bidding a number of proposals, including approximately $800,000 for the NASA COTS proposal during 2006, as well as absorbing a larger marketing and sales organization as part of the merger with Starsys. Unfortunately, SpaceDev did not win the COTS contract.

On June 19, 2014 Sierra Nevada Corporation (SNC), headquartered in Sparks, Nevada, announced that it has signed a definitive purchase agreement to acquire the Orbital Technologies Corporation (ORBITEC) as a wholly-owned subsidiary of SNC. ORBITEC is a leading subsystems integrator and high technology development company based in Madison, Wisconsin. ORBITEC's strong liquid rocket propulsion, life science and support, and fire suppression technology portfolio will enhance both SNC Space Systems' Propulsion and Spacecraft Systems' product lines.

. ORBITEC is the lead for the Environmental Control and Life Support Systems (ECLSS) and Thermal Control Systems (TCS) for SNC, providing reliable living conditions including temperature and humidity control to support the astronauts during their journeys on SNC's Dream Chaser® spacecraft. Recently, SNC selected ORBITEC to provide the RCS engines for Dream Chaser using green, nontoxic propellants.

SpaceDev has begun designing a reuseable, piloted, sub-orbital space ship that could be scaled to transport passengers to and from Low Earth Orbit, including the International Space Station. The name of the vehicle is the SpaceDev Dream ChaserT. SpaceDev signed a non-binding Space Act Memorandum of Understanding with NASA Ames Research Center, which confirmed SpaceDev's intention to explore novel, hybrid propulsion based hypersonic test beds for routine human space access. SpaceDev will explore with NASA collaborative partnerships to investigate the potential of using SpaceDev's proven hybrid propulsion and other technologies, and a low cost, private space program development approach to establish and design new piloted small launch vehicles and flight test platforms to enable near-term, low-cost routine space access for NASA and the United States.

Unlike the more complex SpaceShipOne, for which SpaceDev provided critical proprietary hybrid rocket motor propulsion technologies and components, the SpaceDev Dream ChaserT would be crewed and launch vertically, like most launch vehicles, and would glide back for a normal horizontal runway landing. The sub-orbital SpaceDev Dream ChaserT would have an altitude goal of approximately 160 km (about 100 miles) and would be powered by a single, high performance hybrid rocket motor, under parallel development by us for the SpaceDev StreakerT, a family of small, expendable launch vehicles, designed to affordably deliver small satellites to Low Earth Orbit. The SpaceDev Dream ChaserT motor would produce approximately 100,000 pounds of thrust, about six times the thrust of the SpaceShipOne motor, but less than one-half the thrust of the 250,000 pounds of thrust produced by hybrid rocket motors developed several years ago by the American Rocket Company.

On September 29, 2004 and October 4, 2004, SpaceDev's hybrid propulsion technology helped propel SpaceShipOne into space flight history as the craft garnered the $10 Million Ansari X Prize, a contest created to stimulate the development of the private sector human space flight industry. SpaceDev provided several critical components and the hybrid rocket technology for the craft's motor, including igniter, injector and main operating valve, which successfully performed as expected and powered SpaceShipOne on its historic manned flight. SpaceShipOne exceeded the altitude requirement on both scheduled flights as required by the Ansari X Prize competition. The hybrid propulsion system burned full duration and pilot Brian Binnie steered SpaceShipOne high above the Mojave, California desert to a height of 367,442 feet altitude (69.5 miles), which far exceeded the required 328,000 feet altitude - a sky-high goal required by the X Prize Foundation of St. Louis, Missouri.

SpaceDev, Inc., including wholly-owned active subsidiary, Starsys, Inc., which was acquired by SpaceDevs on January 31, 2006, is engaged in the conception, design, development, manufacture, integration, sale and operation of space technology systems, subsystems, products and services, as well as the design, manufacture, and sale of mechanical and electromechanical subsystems and components for spacecraft. We are currently focused on the commercial and military development of low-cost small satellites and related subsystems, hybrid rocket propulsion for space and launch vehicles, subsystems that enable critical spacecraft functions such as pointing solar arrays and communication antennas and restraining, deploying and actuating moving spacecraft components.

The acquisition of Starsys on January 31, 2006 fundamentally changed the SpaceDev profile. Starsys was insolvent at the time of the merger. SpaceDev's historic business had 2005 revenues of approximately $9.0 million and a 2005 profit of approximately $0.5 million. Starsys is a mature operating company with 2005 revenues of approximately $18 million and 2005 losses of approximately $3.4 million. In 2006, SpaceDev and Starsys merged and had combined revenues of approximately $32 million and losses of less than $1.0 million.

During 2006, approximately 89% of net sales were generated from direct government contracts, and from government-related work through subcontracts with others, while the remaining 11% was generated from commercial contracts. In 2005, approximately 98% of net sales were generated from direct government contracts and from government-related work through subcontracts with others, while the remaining 2% was generated from commercial contracts. The mix shift was primarily due to the January 2006 acquisition of Starsys.

In 2009, SNC acquired SpaceDev Inc. Other accounts related that in 2008, SNC acquired SpaceDev, an aerospace and defense industry company. Read more: http://www.digitaljournal.com/tech-and-science/technology/sierra-nevada-s-dream-chaser-to-fly-first-un-mission-in-2021/article/476025#ixzz4ix9HP0tg SNC's reusable Dream Chaser spacecraft is a multi-mission, commercial, lifting-body vehicle capable of transportation services to low-Earth orbit (LEO) destinations, including the International Space Station (ISS). SNC has developed one common Dream Chaser spacecraft airframe, which we call a Space Utility Vehicle (SUV) due to its mission flexibility. However, there are currently two Dream Chaser variants optimized specifically for either uncrewed or crewed missions, known as the Dream Chaser Cargo System and Dream Chaser Space System, respectively. Additional variants may be developed for future mission needs.

The Dream Chaser Spacecraft Airframe Features Include:

• Lifting-body spacecraft with the same outer mold line (shape)
• Capable of autonomous launch, flight and landing (does not require a pilot)
• High reusability
• Low 1.5 g atmospheric entry throughout the entire flight profile
• Gentle runway landing on any compatible commercial runway, both in the United States and internationally
• Immediate access to crew or cargo upon landing
• All non-toxic consumables, including propellants - a historic first!
• Ability to perform an ISS propulsive reboost when docked (lifts ISS to a higher orbital altitude)

The Dream Chaser Cargo System is designed to deliver up to 5,500 kg of pressurized and unpressurized cargo to the ISS with the ability to conduct orbital disposal services and responsively return pressurized cargo at less than 1.5 g’s to a gentle runway landing. This solution meets or exceeds NASA’s current cargo transportation requirements.

Addition of an environmental control, life support system and seating capable of transporting a crew of seven and critical cargo to LEO. Launches without a fairing, on top of a human-rated United Launch Alliance Atlas V rocket with the ability to safely abort to a runway in the event of an emergency

SNC’s Dream Chaser spacecraft has been in development for more than 10 years, including six years as part of NASA’s Commercial Crew Program, and leverages more than 40 years of X-vehicle and NASA space shuttle heritage. To date, SNC has received funding from NASA and has made its own significant investments to mature the Dream Chaser vehicle. SNC’s Dream Chaser spacecraft leverages over 40 years of NASA X-vehicle and Space Shuttle heritage.

With Boeing and SpaceX receiving the coveted commercial crew transportation contracts in September 2014 to ferry NASA astronauts to and from the International Space Station (ISS) beginning in 2017, Sierra Nevada Corporations’ Dream Chaser (DC) space plane was left out in the cold.

According to am October 2014 study document released by Vulcan Aerospace Corporation and SNC, the companies “have collaborated on a space transportation architecture, utilizing the Stratolaunch aircraft as a launch platform and the Dream Chaser spacecraft as the payload.” In this configuration, DC would be a 75 percent sized variant of the DC spacecraft designed as part of NASA’s crew transportation contract program. As noted in the study document, “even with a smaller scale, the scale DC can achieve a comparable mission length to the commercial crew variant." n total, the scaled version of DC would be 22.5 feet in length, contain a fin tip-to-tip wingspan of 18.2 feet, be able to carry a maximum of two crewmembers to ISS and three crewmember LEO (Low Earth Orbit) destinations.

On January 14, 2016 NASA competitively selected Sierra Nevada Corporation’s (SNC) Space Systems to receive a multi-year contract to provide cargo delivery, return and disposal services for the International Space Station (ISS). SNC received a Commercial Resupply Services 2 (CRS2) contract, to fulfill a minimum of six cargo delivery service missions to and from the ISS utilizing SNC’s Dream Chaser Cargo System. NASA’s selection of SNC for the CRS2 program will enable spacecraft reusability and runway landings for United States’ cargo delivery and access to the ISS through 2024.

By July 2016 the Dream Chaser full-scale, flight test vehicle was ready for transportation to NASA’s Armstrong Flight Research Center (AFRC) in California where Phase Two flight tests will be conducted in coordination with Edwards Air Force Base (AFB). Dream Chaser program upgrades and initial hardware testing were completed at the Louisville, Colorado spacecraft assembly facility, and within the next several weeks the same Dream Chaser vehicle that conducted Phase One flight testing will arrive at NASA’s AFRC. Upon arrival, SNC will begin a series of pre-flight ground evaluations to verify and validate the vehicle’s system and subsystem designs. After successful completion of all ground testing, Dream Chaser will begin its Phase Two free-flight testing. These activities are being conducted through a Space Act Agreement with NASA’s Commercial Crew Program (CCP).

The vehicle will undergo a series of tests building on those performed in Phase One, including tow-tests, pre-flight tests and ending with free-flight testing. SNC is also performing additional critical tests to validate the Dream Chaser’s orbital flight software and calculate the spacecraft's handling and performance characteristics. Along with other pre-flight and post-flight evaluations, this data will be used to confirm Dream Chaser’s subsonic aerodynamic properties as well as flight software and control system performance requirements.

Sparks, Nevada-based Sierra Nevada Corp. (SNC) is a privately-held company that was formed in 1963. Sierra Nevada Corporation provides customer-focused technology solutions in the areas of aerospace, aviation, electronics and systems integration. SNC has been honored as one of “The World’s Top 10 Most Innovative Companies in Space,” and one of America’s fastest growing companies. SNC’s Space Systems business area based in Louisville, Colorado, designs and manufactures advanced spacecraft, space vehicles, rocket motors and spacecraft subsystems and components for the U.S. Government, commercial customers, as well as for the international market. SNC has more than 25 years of space heritage, participating in more than 450 successful space missions and delivering 4,000+ systems, subsystems and components around the world.

Under the leadership of CEO Fatih Ozmen and President Eren Ozmen, SNC has a workforce of over 3,000 personnel in 30 locations in 16 states. SNC's six unique business areas are dedicated to providing solutions to SNC's customer base.

Sierra Space announced 31 May 2022 a strategic partnership with aerospace manufacturer Spirit AeroSystems for production of cargo modules for its Dream Chaser vehicles. The companies said they signed a letter of intent under which Spirit will assist in the development and production of Shooting Star, the cargo module attached to the aft end of the Dream Chaser lifting body vehicle. That module will support future cargo missions to the International Space Station under Sierra Space’s contract with NASA, and for other applications.

Shooting Star can carry about 4,500 kilograms of pressurized and unpressurized cargo, and also has solar panels and thrusters. While the Dream Chaser itself returns to Earth to fly additional missions, the Shooting Star module is jettisoned before reentry and burns up in the atmosphere, meaning a new module is needed for each mission.

Sierra Space built the first Shooting Star module on its own, but suggested that partnering with Spirit, a company best known for producing aircraft structures, can lower costs for future modules. “Shooting Star is another innovative technological solution from Sierra Space for the new space economy, and with Spirit as a key partner, we are broadening accessibility to our offering and increasing efficiencies to accelerate more widespread adoption,” Tom Vice, chief executive of Sierra Space, said in a statement.

“Spirit AeroSystems brings unparalleled value in terms of design for manufacturability and industrialization to help scale production rates on the Dream Chaser and its derivatives,” said Tom Gentile, president and chief executive of Spirit AeroSystems. Gentile thanked Sen. Jerry Moran (R-Kan.), who serves on both the Senate Commerce Committee and the appropriations subcommittee that funds NASA, for bringing the two companies together. Spirit is headquartered in Wichita, Kansas. Besides producing Shooting Star cargo modules for future ISS cargo missions, the companies said in the statement that, through the partnership, they will “expand the versatility of variant designs in support of future Sierra Space cargo and service missions.”

Researchers with the Department of Energy’s Oak Ridge National Laboratory and Sierra Space Corporation developed a new silicon-carbide-based thermal protection system, or TPS, for reusable commercial spacecraft. The TPS is composed of a tile face made from advanced materials and an insulative tile backing that, when installed on a space vehicle, will be able to withstand multiple launches and the extremely high temperatures of atmospheric re-entries over short periods of time.

The TPS composite material merges the high temperature and corrosion stability properties of silicon carbide with the high strength and high temperature consistency of carbon fiber. The two materials are combined into a low-density, low-profile composite thermal barrier that is critical for providing both insulative protection and stable flight dynamics.

“Keeping a consistent outer mold line is important for reusability,” said ORNL principal investigator Greg Larsen November 14, 2024, referring to the need for a smooth exterior surface. “It keeps the aerodynamics the same to allow the vehicle to fly as designed.” Larsen explained the properties of the new tile will help maintain the aerodynamic surface over multiple flights by resisting changes to size and shape caused by exposure to extreme heat. The TPS material’s light weight will help maximize usable commercial payload and internal vehicle volume.

The team leveraged 30 years of lessons learned from NASA’s Space Shuttle program to develop the new TPS. First used in 1981, the NASA shuttle orbiter’s TPS is still considered state-of-the-art thermal protection technology for space vehicles. The design called for each shuttle to be fitted with more than 24,000, six-inch by six-inch silica-fiber thermal barrier tiles – every piece custom made to fit an exact location on the surface of the lower portion of the spacecraft. The tiles were formed in a labor-intensive process by pouring water and chemicals into a mold and sintering the mixture at a temperature of up to 2,350 degrees Celsius to create the final shape. Technicians used a special adhesive to attach the individual tiles to the outer skin of each orbiter.

According to Larsen, while the NASA program averaged nearly five launches per year, commercial space flight is moving at a faster pace today. “The key to achieving a flight cadence that is driven by fast landing-to-launch turnaround times is reusability of the TPS,” he said. “The materials we are exploring will push the boundaries of reusability that translate directly to commercial viability for space-access providers.”

ORNL and Sierra Space completed the first material-development phase of the project and have jointly applied to patent the new material. The second phase of the project will focus on developing an enhanced manufacturing process that will produce the insulative tile backing. Sierra Space planne to use the new TPS on the Sierra Space Dream Chaser, the first-ever winged commercial spaceplane. The multi-mission spaceplane fleet is designed to transport crew and cargo to low-Earth orbit. The company plans to use the new TPS on the DC100 Dream Chaser that will carry critical supplies and science experiments to and from the International Space Station under a NASA Commercial Resupply Service contract.

Huntsville International Airport (HSV) has the infrastructure in place to support the landings. Huntsville has a long history of working in the space and payload industry. A NOTAM will be issued for each reentry opportunity. Runway 18L-36R would remain closed for up to 10 hours or until the Dream Chaser is unloaded and in safe condition. HSV Operations would inspect the runway prior to returning to normal aircraft operations. Runway 18R-36L would be closed briefly.

The nominal reentry location would be the existing SLF Runway 15/33 at the Cape Canaveral Spaceport in Brevard County, Florida (Figure 2-1). If Dream Chaser is unable to safely land at the SLF, but able to safely land at another location, VSFB Runway 12/30 in Santa Barbara County, CA (Figure 2-2) would be utilized for reentry operations. In the event that the Dream Chaser is unable to safely land at either the SLF or VSFB, Dream Chaser would conduct an emergency landing in the broad open ocean and would be expected to sink.

The FAA is the lead agency, and U.S. Coast Guard, National Aeronautics and Space Administration, U.S. Fish and Wildlife Service, National Marine Fisheries Service, and National Park Service are cooperating agencies for the draft EA due to their special expertise and jurisdictions. The FAA began 12 July 2024 evaluating Sierra Space Corporation's (Sierra Space's) proposal to conduct Dream Chaser reentry operations at the Shuttle Landing Facility (SLF) in Brevard County, Florida or the Vandenberg Space Force Base (VSFB) in Santa Barbara County, California, which would require the FAA to issue a license. Issuing a license is considered a federal action subject to environmental review under NEPA. Under the Proposed Action, the FAA would issue a license to Sierra Space, which would authorize Sierra Space to conduct reentry operations of its Dream Chaser vehicle at the SLF or VSFB. If Sierra Space does not obtain a license for reentry operations at the SLF or VSFB, they would be unable to conduct reentry operations of their Dream Chaser vehicle.

In 2016, NASA awarded a Commercial Resupply Services-2 contract to Sierra Space, formerly part of Sierra Nevada Corporation, to resupply the International Space Station with its Dream Chaser spaceplane and companion Shooting Star cargo module. As part of its contract, Sierra Space was awarded a minimum seven flights, and the agency previously issued firm-fixed price task orders for four Dream Chaser resupply missions based on the needs of the space station.

On 25 September 2025, NASA and Sierra Space mutually agreed to modify the contract as the company determined Dream Chaser development is best served by a free flight demonstration, targeted in late 2026. Sierra Space will continue providing insight to NASA into the development of Dream Chaser, including through the flight demonstration. NASA will provide minimal support through the remainder of the development and the flight demonstration. As part of the modification, NASA is no longer obligated for a specific number of resupply missions; however, the agency may order Dream Chaser resupply flights to the space station from Sierra Space following a successful free flight as part of its current contract.

“Development of new space transportation systems is difficult and can take longer than what’s originally planned. The ability to perform a flight demonstration can be a key enabler in a spacecraft’s development and readiness, as well as offering greater flexibility for NASA and Sierra Space,” said Dana Weigel, manager of NASA’s International Space Station Program. “As NASA and its partners look toward space station deorbit in 2030, this mutually agreed to decision enables testing and verification to continue on Dream Chaser, as well as demonstrating the capabilities of the spaceplane for future resupply missions in low Earth orbit.”

NASA, and its commercial and international partners, will continue to supply the orbital complex with critical science, supplies, and hardware as the agency prepares to transition to commercial space stations in low Earth orbit. NASA continues to work with a variety of private companies to develop a competitive, space industrial base for cargo services, which will be needed for future commercial space stations. With a strong economy in low Earth orbit, NASA will be one of many customers of private industry as the agency explores the Moon under the Artemis campaign and Mars along with commercial and international partners.

By October 2025 the first vehicle, Tenacity, was at Kennedy Space Center completing pre-flight testing, including electromagnetic interference testing. Upcoming milestones included a captive tow test in early November 2025, acoustic testing, an integrated hot-fire test, and mission systems testing. Plans called for launch on a ULA Vulcan rocket in Q4 2026 into an ISS-like orbit for several days of flight demonstrations before landing. Sierra Space was seeking new customers for the first flight, including potential satellite deployments, and positioning Dream Chaser to serve national security, NASA, and commercial partners.

A second spaceplane named Reverence was in early production at Sierra Space's Louisville, Colorado facility. The pivot away from guaranteed ISS cargo missions represents Sierra Space's strategy to expedite first flight while maintaining flexibility for diverse customers, though it also reflects the reality of ISS's planned 2030 end date and ongoing certification challenges.