Integration and Testing of Cygnus Service Modules

January 2012

Integration and testing of Cygnus spacecraft service modules continues at our Dulles, VA Satellite Manufacturing Facility (SMF). The service module on the left in the photo below will be used for the Commercial Orbital Transportation Services (COTS) demonstration flight to the International Space Station (ISS) later this year. The service module on the right will carry out the first of eight cargo resupply missions under Orbital's Commercial Resupply Services (CRS) contract with NASA, also scheduled for later this year. A third Cygnus service module (not shown) is also undergoing integration in a separate clean room facility in the facility.

The two service modules shown below are being integrated and assembled in a class 100,000 clean room prior to the beginning of environmental testing, the last major phase of the spacecraft development and testing prior to shipment to the Wallops Island, VA launch site, where it will be integrated with the Pressurized Cargo Module (PCM) that was delivered in 2011. The Cygnus service module on the left will begin its thermal vacuum testing in February, followed by mechanical environmental tests one month later. The banner seen on the wall above the Cygnus service modules is a full-scale depiction of the complete Cygnus system with its solar arrays deployed.

To view other photos, images and video animation of the launch sequence of Orbital's Cygnus spacecraft and the Antares launch vehicle that will carry the Cygnus into orbit, click on the Images Multimedia link above.

Cygnus Enhanced Spacecraft to Use Ultraflex™ Solar Arrays

November 2011

Orbital has selected lightweight ATK Ultraflex solar arrays to power its enhanced Cygnus cargo logistics module beginning with the fourth mission under Orbital's Cargo Resupply Services agreement with NASA to provide cargo logistics services to the International Space Station. The enhanced Cygnus variant incorporates a larger pressurized cargo module that can carry up to 2700 kg of crew supplies, spares and scientific experiments to the ISS. Measuring more than 11 feet in diameter, the Ultraflex arrays will provide the same power as the arrays to be used in the first three Cygnus missions but with significantly reduced mass.

Updated Taurus II & COTS/CRS Development & Flight Milestones

October 2011

Orbital has released an updated milestones chart to the reflect the most current projections for the integration, testing and operations of its Taurus II and Cygnus spacecraft for the COTS and CRS programs.

Click here to view pdf

The Latest on Taurus II and Cygnus

October 2011

Here are the latest scenes from our operations at Wallops Island launch site:

And at our Dulles satellite production and test facility:

First Pressurized Cargo Module Arrives at Wallops

August 2011

Ferried aboard an Antonov An-26 aircraft, a cargo container containing the first Cygnus Pressurized Cargo Module (PCM) arrived at the Wallops Flight Facility, Virginia on Thursday, August 24. The PCM was transported to NASA's H-100 payload processing facility where it will be mated to the Cygnus service module. Together, the PCM and the service module will form the first operational Cygnus that will be launched to the International Space Station to carry out a demonstration mission under the Commercial Orbital Transportation Services (COTS) joint NASA and Orbital research and development program. The COTS demonstration mission is currently scheduled for early 2012. Designed to carry approximately 2,000 kg of cargo, the PCM was manufactured by Thales Alenia Space in Turin, Italy. Integration and testing of the service module continues at Orbital's Satellite Manufacturing Facility in Dulles, Virginia.

Updated Taurus II & COTS/CRS Development & Flight Milestones

July 2011

Orbital has released an updated milestones chart to the reflect the most current projections for the integration, testing and operations of its Taurus II and Cygnus spacecraft for the COTS and CRS programs.

First Cargo Module Ships. Service Module Integration Continues.

June 2011

The first Pressurized Cargo Module (PCM) for Orbital's COTS demonstration mission completed Qualification and Hardware Acceptance Reviews at Thales/Alenia's facility in Turin Italy. The PCM and its Ground Support Equipment will now be prepared for shipment from Italy to the Wallops Island Virginia launch site. Read about the PCM in this news release from Thales/Alenia.

As the PCM makes its way to the launch site, integration and testing of the Cygnus Service Module for the COTS demonstration mission continues in Orbital's Dulles, Virginia Satellite Manufacturing Facility. The Service Module completed its Open Panel assembly activities and will transition to its Initial Integrated Systems Testing.

Upon completion of all its testing, the Service Module will be shipped to Wallops Island, where it will be mated to the PCM. The fully assembled Cygnus spacecraft will then be attached to Orbital's new Taurus II rocket and launched to the International Space Station to demonstrate the delivery of supplies and payload items. See the Taurus II Microsite for more progress updates.

Updated Taurus II & COTS/CRS Development & Flight Milestones

April 2011

Orbital has released an updated milestones chart to the reflect the most current projections for the integration, testing and operations of its Taurus II and Cygnus spacecraft for the COTS and CRS programs.

Updated Taurus II & COTS/CRS Development & Flight Milestones

February 2011

Orbital has released an updated milestones chart to the reflect the most current projections for the integration, testing and operations of its Taurus II and Cygnus spacecraft for the COTS and CRS programs.

Cygnus Mission Overview Video

NASA Deputy Administrator Lori Garver Visits Orbital Dulles, Virginia Facility

January 2011

NASA Deputy Administrator Lori Garver and Jim Kohlenberger, Chief of Staff of the White House Office of Science and Technology Policy recently visited Orbital’s Dulles, Virginia campus. After a brief overview of the company and its programs, Ms. Garver, Mr. Kohlenberger and other NASA guests took a tour of Orbital’s mission operations center where it will direct its commercial logistics missions to deliver supplies to the International Space Station.  The group also toured the company’s satellite manufacturing facility where they viewed a mock-up of the Cygnus spacecraft which will carry supplies to the Space Station, as well as work in progress on the first Cygnus spacecraft.  In addition, the guests were briefed on Orbital’s manufacturing and test facilities and viewed several satellites in production – both NASA scientific spacecraft and commercial communications satellites.

Orbital Completes Cargo Integration Demonstration

December 2010

A team of Orbital and Thales Alenia Space (TAS) engineers and technicians recently completed a COTS program milestone when it successfully performed a Cargo Integration Demonstration in Turin, Italy, where the Cygnus Pressurized Cargo Modules (PCMs) are being built and tested. The demonstration was one of the milestones in Orbital’s Space Act Agreement with NASA and marked another significant achievement for the program.

TAS technicians performed the demonstration, which was witnessed by Orbital and NASA engineers, managers, astronauts and flight controllers. The demonstration was performed using a PCM flight unit, production Ground Support Equipment (GSE) and simulated pre-packed cargo bags and cargo volume mock-ups.

The process included a complete volumetric loading of a standard PCM to demonstrate access to every cargo stowage location using a variety of different sized cargo transfer bags. The demonstration milestone called for the installation of at least one cargo bag of the maximum allowable mass in the least-accessible-location in the cargo module to validate the most extreme cargo capabilities anticipated, as well as a “virtual reality” demonstration of cargo module unloading during operations on orbit, an activity that cannot be adequately simulated in the Earth-gravity environment. In addition, the assembly of an internal stowage structure was performed using tools typically found on the ISS.

The demonstration was a 100% success, with all bags and simulators installed, strapped and tensioned. This demonstration gave the Orbital-NASA team confidence that the cargo accommodation system developed for ground and space operations will meet the strict operational requirements of human spaceflight.

The photos below show the Cygnus PCM packed with simulated cargo in the types of bags actually used in ISS operations.

NASA Administrator Visits Orbital for Mission Operations Center Dedication Ceremony

November 2010

NASA Administrator Charles E. Bolden, Jr. joined Orbital's Chairman and CEO David Thompson in a ceremonial ribbon cutting ceremony to mark the completion of a new facility that will serve as the Mission Operations Center (MOC) for the company’s cargo logistics missions to the International Space Station (ISS) for NASA that begin in 2011.

The Mission Operations Center will be dedicated to the COTS and CRS programs, providing command and control systems for the ISS logistics missions.  The MOC features with direct connectivity with NASA’s Johnson Space Center in Houston, TX for full interoperability between Houston and the ISS.

While at Orbital’s Dulles, VA facilities, the NASA delegation toured Orbital’s satellite manufacturing facility where they viewed the service module for the first Cygnus spacecraft that will demonstrate commercial cargo delivery services to the ISS, and a full-scale mock-up of the Cygnus spacecraft.  During the tour the delegation also viewed several of the 15 spacecraft currently in production in the facility that will be launched in the coming years.

Cygnus Primary Structure Completes Static Load Testing

October, 2010

The Cygnus Service Module primary structure successfully completed its static load testing in October at Applied Aerospace Structures Corp. in Stockton CA. The test program applied loads to the structure to simulate the forces that it will experience during a Taurus II launch while carrying a fully loaded Pressurized Cargo Module on top. For the load case that simulated the maximum axial acceleration of the rocket, almost 90,000 lb were applied to the cargo module interface ring, which is equivalent to supporting a dry Boeing 737 on top of the structure. Other load cases applied about 35,000 lb to the sides of the structure. The structure performed well during the test and is now being prepared for shipment to Dulles to start integration and test.

Major Software Integration Milestone Completed, PCM Production in Full Gear

September 2010

Over the course of three weeks in August and early September, the NASA/Orbital Joint Avionics Test #2 (JT2) was held at the NASA Station Development and Integration Laboratory (SDIL) near Johnson Space Center in Houston, Texas. This early integration test of the International Space Station (ISS) and Cygnus flight software involved personnel from NASA, Orbital, Boeing and Mitsubishi Electric Company, and Orbital’s processor-in-the-loop testbed (pictured below left).

The purpose of the test was to ensure that Cygnus and ISS flight software were capable of communicating via both berthed and proximity communications system links. The primary objective of the test was to demonstrate basic command and telemetry data routing between the ISS and Cygnus flight software. A number of secondary objectives were included as well.

During the course of the test, Orbital engineers were able to fully demonstrate 16 out of the 21 design verification objectives required to satisfy NASA requirements. This was a remarkable accomplishment given that this was the first time the NASA, JAXA, and Orbital hardware and software had been physically integrated into a working system. Orbital will return to the SDIL in November 2010 with final integration testing slated for March 2011.

Meanwhile, at Thales/Alenia Space in Turino Italy, production of the Pressurized Cargo Modules (PCM) continues at a robust pace as evidenced by the image below right of two PCMs on the production floor. Structure welding on the last standard configuration PCM was completed in late September. Delivery of the first PCM to Orbital is currently planned for Q1 2011. (image courtesy of Thales/Alenia Space).

Cygnus Pressurized Cargo Module Completes Proof-Pressure Testing

August 2010

The first Cygnus Pressurized Cargo Module successfully completed proof-pressure testing (top photo) at the Thales/Alenia production facility in Italy. Testing went as planned with no anomalies noted. The interior pressure of the PCM was increased up to 1.4 times normal value for the test.

The PCM hatch (middle photo) was mated to the PCM cargo module in preparation for proof pressure testing. The internal hatch view (bottom photo) shows the hatch rails that will be used to restrain the hatch when crews open the hatch on orbit. The PCM hatch also recently completed qualification tests at Thales. The PCM hatch has a strong resemblance to the current hatches used on the US-segment of the ISS. However, at 37 inches on each side, it is somewhat smaller than the 50 inch ISS hatch. The hatch size will accommodate all cargo currently planned by NASA for the Cygnus vehicle.

Updated Taurus II and COTS/CRS Development & Flight Milestones

July 2010

Orbital recently completed a re-planning exercise for the Taurus II and Cygnus programs, with several notable changes anticipated. The company has maintained its schedule to launch the first Taurus II rocket in late June 2011; however, the mission will likely be a new risk-reduction test flight, not the first COTS demonstration mission. This new flight on the manifest is included in NASA's budget request to add $312 million in additional funding to the COTS program, which is now making its way through the Congressional approval cycle. For the risk reduction test flight, Taurus II would not carry a full-fidelity Cygnus spacecraft – instead, a payload simulator would be launched to verify the design and flight performance characteristics of Orbital's new medium class launcher.

If the Test Flight funding is approved and an additional mission is inserted into the schedule, the original COTS demonstration mission would be carried out later in 2011. In this COTS demonstration mission, a fully functional Cygnus spacecraft will be launched by Taurus II and will rendezvous and berth with the International Space Station, performing the identical operations as a CRS mission and fully demonstrating the cargo delivery service.

Finally, if the Test Flight is approved, the updated launch schedule pushes the first operational CRS mission to the beginning of 2012, as reflected in the chart below.

The First Cygnus Pressurized Cargo Module Takes Shape in Italy

May 2010

The first Cygnus Pressurized Cargo Module (PCM) is taking shape at the Thales/Alenia Space facility in Turin, Italy. The standard PCM configuration shown in the photos will be utilized in the Commercial Orbital Transportation Services (COTS) demonstration mission slated for Spring 2011. Capable of transporting up to 2,000 kg to the International Space Station, this PCM will serve as the pathfinder for identical modules that will utilized in the first two Cargo Resupply Services (CRS) missions in 2011 and 2012 (see mission manifest for a complete listing).

(Images Courtesy Thales/Alenia Space)

Updated Taurus II and COTS/CRS Development & Flight Milestones

April 2010

Orbital recently updated its Taurus II and Cygnus development and flight milestones leading to the first launch, which will be the COTS demonstration mission. The revised time line is posted below. Note that the time line is intended to offer general insight into the programs' major milestones and is subject to change.

Orbital Unveils Full Scale Cygnus Model

April 2010

Earlier this month, Orbital displayed a full-scale model of the Cygnus cargo delivery spacecraft at the National Space Symposium (NSS) that took place in Colorado Springs, CO from April 12 to 15. The NSS is one of the space industry’s marquee events each year, attracting thousands of professionals involved in defense and intelligence, civil government and commercial space programs. Silhouetted against a fireworks illuminated sky, Cygnus truly was the star of the show this year.

Orbital Sr. VP Frank Culbertson's Testimony before the Senate Commerce, Science and Transportation Committee’s Subcommittee on Science and Space

March 18, 2010

Good afternoon Chairman Nelson and Ranking Member Vitter, and members of the subcommittee.  I appreciate this opportunity to participate in this hearing regarding the potential of commercial crew delivery capabilities to low Earth orbit to enhance our nation’s progress in space exploration and development. 

I am honored to sit on this distinguished panel with industry colleagues Michael Gass and Gwynne Shotwell, and former NASA colleagues George Nield, now with the FAA, and Malcolm Peterson, formerly NASA’s comptroller.  Needless to say, it is also an honor to sit alongside two fellow astronauts whom I hold in the highest regard: Lt. General Thomas Stafford, who commanded the vital Apollo 10 lunar landing dress rehearsal mission and 35 years ago blazed a trail for U.S.-Russian cooperation in space while commanding the American side of the Apollo-Soyuz mission, and Bryan O’Connor, a veteran of two Space Shuttle missions and since 2002 the NASA leader and agency conscience on all matters regarding mission safety. 

For those of us who have had the great privilege to fly into space wearing the U.S. flag on our space suit—including the chairman of this subcommittee—I think it is fair to say that we are oriented toward achieving mission success through thoughtful risk taking.  Every time I have entered the Space Shuttle preparing for flight it was with the utmost confidence that the dedicated men and women of NASA and its contractor teams had done everything humanly possible to ensure my safety, and I’m certain my colleagues share this view about their experiences.

My job at Orbital Sciences Corporation includes oversight of all programs relating to Human Space Flight Systems, including not only our Cargo Resupply Services contract and the Cygnus Spacecraft, with a close connection to our Taurus II Launch Vehicle, but also the development of the Orion Launch Abort System under the auspices of the Constellation Program.  In addition to our 28 years of work in other areas of spaceflight, such as satellites and launch vehicles, our company is totally committed to supporting the future of human space flight in this country, as well as to exploring business approaches that will continue to make space more accessible and productive for all potential users.

The recent CCDev procurement competition, with 36 bidders listed, indicates that a number of U.S. companies, large and small, with outstanding track records of providing NASA with launch and space services have an interest in supporting commercially provided crew transportation services.

NASA’s proposed funding of about $6 billion over the next five years, together with the addition of appropriate private capital, should be sufficient to enable at least one and probably two U.S. commercially-provided crew systems to be demonstrated by the year 2015. 

I am confident that NASA can work with commercial providers to establish the proper safety and performance standards and oversight measures, the fundamentals of which are already well-established, that will enable industry to continue this successful era of U.S. human space flight for both U.S. government missions, and for other markets as they develop.  I would also expect that industry will make proper use of NASA’s manpower, expertise, and physical infrastructure to not only enhance safety and mission success, but also to help maintain and build our national competence in these areas.  Preeminence in exploratory and technical accomplishments remains as important as ever if we are to maintain our global leadership in space and continue to motivate future generations to do the hard work required to carry that banner.

Given your appropriate concern as to whether the commercial space industry is robust enough to develop reliable commercial launch services for crew to low Earth orbit within a reasonable time, at a fair cost, and, most importantly, with the requisite safety margins, let me clearly state again my response to the fundamental question of whether this model can work.  Orbital believes, as do I, that U.S. industry, given the right conditions, relationships, and investments, should be able to develop and demonstrate safe and reliable crew transportation systems for International Space Station support by 2015. 

Two of the important elements of ensuring safety in future transportation systems are close cooperation with NASA in developing a clear understanding and full  implementation of Human Rating Standards, especially at the system level, and a robust, reliable crew escape system.  Furthermore, once such a service is developed, tested, and certified, I would be happy to volunteer to strap in once again for a mission to the International Space Station.  If I am not willing to join the first mission of an Orbital developed spacecraft that I share responsibility for, then no one should be on that flight. 

I would also like to emphasize the importance of partnership to the success of a commercial crew transportation program.  For programs of this nature to work, especially in the NASA context, what’s required is a sound, trusting relationship between - and open, honest communication amongst - the appropriate government, industry, and international partners.  This is not a simple or easy task, as evidenced by the major space programs of the last 50 years, but it can be done and results in powerful accomplishments, such as Apollo, Shuttle, and the International Space Station.  

I do not envisage commercially provided crew services being conducted entirely by industry with a hands-off approach from NASA.  Nor can these commercial services be provided efficiently with traditional levels of government involvement and oversight at every turn.  Rather, to be successful, commercial suppliers must work closely with NASA and other potential customers at key milestones, tests, and reviews, providing insight to the program and demonstrating the willingness to listen to the technical judgment and leadership of NASA’s seasoned government and contractor human spaceflight team in a mutually productive relationship.  In addition, the FAA relationship must continue to grow and mature in order to establish a proper regulatory regime for commercial crew activities.  In this serious business there is no substitute for open lines of communication and the appropriate balance of insight and oversight that will lead to shared progress in 21st century space activities. 

Just as the Shuttle-Mir Program was an excellent developmental program for producing the collaboration and joint operations being used so successfully in the International Space Station Program, the Commercial Orbital Transportation program and related Commercial Resupply Services program or COTS/CRS, are providing superb learning experiences for not only developing new hardware that can fly to the Station safely, but also the operations concepts, relationships, and lines of communication that will enable all sorts of commercial endeavors in the future.

Though the willingness of industry to invest their own technical and financial resources in an incipient space project is not new, just as Orbital is now doing on the COTS/CRS programs, the levels of investment and financial risks are moving in new directions.  We see the opportunity for commercially provided crew transportation as an extension and strengthening of NASA’s current initiatives in commercial cargo delivery that will lead to exciting new partnerships with private industry.  The challenge is to develop and operate commercial low Earth orbit transportation systems that will service not only the government but also the other markets that can be imagined.

Since 2008 Orbital has been fully engaged as one of two companies contracted to provide the delivery of crew and cargo to the International Space Station.  Although this has been a huge development program for a company of our size, and unprecedented in scope for a purely commercial venture between a private company and NASA, I am very pleased to report that from Orbital’s perspective, and that of our shareholders, we have made steady and valuable progress.  We expect to have achieved all but 3 of 21 NASA program milestones by the end of this year, including successful completion of the critical Phase One and Phase Two Safety Review milestones.  We are on pace for first launch of the Taurus II rocket from Launch Pad O-A at the Mid-Atlantic Regional Spaceport on Wallops Island, Virginia, next year.  This progress is possible because of the hard work and cooperation of many talented people at NASA Headquarters and several NASA centers, as well as the FAA, the support of Virginia and Maryland through the Mid-Atlantic Regional Spaceport Authority, the efforts of our teammates, suppliers, and international providers, and the internal corporate support we receive to resource this program.

I mention all of those players to highlight the point that it truly takes a complex mix of organizations to execute space missions, especially with crew involved.  The mix and complexity have evolved over the last five decades, but this is still one of the most difficult and exciting endeavors known to humans, and I believe will be for some time to come.  The addition of local and state agencies and organizations in new roles and levels of investment will only serve to enhance commercial opportunities for success.  Executing parts of the development and operation in new and imaginative ways, while keeping the focus on safety and mission success, is our challenge for the near term, so that we not only expand our frontiers, but also give our children a space program that they can build upon – not be forced to rebuild.

For Orbital, we see the extension of the International Space Station as one of the cornerstones for a sound future in space, both scientifically and commercially, as we strive for more distant destinations and new technologies continue to be developed.  Looking forward, we believe the ability to provide cargo and crew services to the International Space Station is absolutely critical given the pending retirement of the Space Shuttle and the Administration’s wise decision to continue the International Space Station’s mission from 2015 to 2020 (or beyond!), thus enabling our scientists and researchers to pursue a more aggressive program of scientific research and utilization at this multi-national orbital facility.  I applaud its designation as a National Laboratory.  In addition, based on my personal experience on board the Station, I firmly believe that the ISS is an ideal platform for developing and simulating the operations, technologies, and techniques for executing more ambitious missions and lengthy missions to the Moon, Mars, and other destinations. 

I often tried to imagine what we would need if the station were en route to Mars or were somehow placed on the moon, besides what we already had or expected to have in the future - such as regenerative life support and radiation protection – and one of the major requirements was a reliable supply line – and/or a lot more room!  We at Orbital intend to be a key element in that supply line.  It is indeed important to recognize that this new approach to meeting our nation’s commitment to fully utilize the International Space Station, including the designated National Laboratory portion of the facility, is part of a broader policy to advance American progress in space on a number of productive fronts.

By now turning anew to America’s innovative private sector to provide crew transport to low Earth orbit, NASA will be able to invest new resources in transformative technologies that will speed our exploration path to the Moon, Mars, asteroids and other deep-space destinations.  New launch vehicle propulsion, in-space operations technologies and related robotic precursor missions are just a few of these.   This approach will also enable increased funding for NASA’s other critical missions in earth and space sciences, thus helping us better protect life on our home planet through accelerated and expanded climate change research missions, and extend through our robotic emissaries and telescopes the profound search for evidence of life in and outside the solar system.

In closing, please allow me to mention that as an astronaut I have had the privilege of working on missions that have helped to enhance our national security, extend international cooperation in space science, and increase the capabilities of the International Space Station facility, which has just been given a new lease on life.  Clearly, the NASA budget that was recently delivered by the Administration has generated a firestorm of discussion that is rarely seen on the topic of space exploration.  I sincerely feel the pain of some who are at the center of the storm, as well as those who feel threatened by parts of the budget, but I welcome the fact that finally we are having a broad and fervent debate on the subject.   I know that  a lot of energy is being expended at NASA to provide increased specificity of the goals, so I am hopeful that a more thoughtful and thorough examination of the available paths forward will result in an ambitious, sound set of programs that will fill us all with pride.  Just as you are doing by holding this hearing, promoting meaningful dialogue within the relatively small but passionate group of people who truly understand and care about what it actually takes to execute what so many take for granted - that is, reliable access to space - will help move us in the right direction.  I expect that U.S. industry will support challenging national space endeavors as it always has –with professionalism, excellence, and innovation.

Our nation continues to inspire people throughout the world for our commitment to freedom, creativity, exploration, and commerce.  Opening the right doors for industry to participate more broadly on a commercial basis will help maintain and enhance America’s leadership on the space frontier.  

Thank you again for inviting me to appear before this important hearing today.

Orbital Sr. VP Frank Culbertson Featured on This Week in Space with Miles O’Brien

March 2010

Frank Culbertson, Senior Vice President for Human Space Systems was a featured guest on This Week in Space with Miles O’Brien on the Spaceflight Now web site. In the eighth edition of the popular podcast of the space-related news program, Culbertson discussed the challenges associated with human rating a commercial spacecraft, the potential for the commercialization of U.S. human spaceflight, and the Obama administration’s new space policy.  To view the podcast, click on either of the links below.  For those who wish to skip directly to the interview, advance the podcast to the 13:42 mark.

Click here to view the podcast on iTunes

Click here to view the video on YouTube

Fabrication of Cargo Module for COTS Demonstration Mission Progressing

February 2010

Fabrication of the pressurized cargo module (PCM) for the Commercial Orbital Transportation Services (COTS) mission is progressing at the Thales Alenia Space - Italia production facility in Torino, Italy. The Cygnus PCM is based on the Thales Alenia Multi-Purpose Logistics Module (MPLM) design which has proven track record of ferrying supplies to the International Space Station via the Space Shuttle.  Delivery of the first flight PCM is scheduled for the 4th quarter of 2010.  Members of the Orbital COTS/CRS program recently traveled to Italy for an update on the PCM manufacturing process.

Systems Testing for Taurus II Begins – First Test of 2nd Stage Motor Successful

December 2009

The Taurus II program officially moved from the engineering design and supplier procurement phase to the testing phase with the successful testing of the Taurus II second stage motor. The solid-fuel Castor 30 motor, which is supplied to Orbital by ATK Space Systems, was test fired at the U.S. Air Force’s Arnold Engineering Development Center (AEDC) in Tennessee. The test lasted a little over 150 seconds and the motor produced about 72,000 lbs. of maximum thrust.  The Castor 30 motor is designed to ignite at altitudes in excess of 100,000 feet, and to accurately test the motor performance, the static fire test was conducted at AEDC using a vacuum chamber specially designed to simulate upper atmospheric conditions.   In addition to the second stage testing, we will soon begin the testing process of the liquid fuel propulsion system for the rocket’s first stage at Stennis Space Center in Mississippi.

Cygnus Solar Array Contract Signed

November 2009

Continuing the international flavor of the COTS/CRS program, we signed a contract with Dutch Aerospace to supply the solar arrays that will help power the Cygnus spacecraft during its mission to deliver cargo to the International Space Station. This is the second Orbital program that Dutch Aerospace has provided solar arrays for. The first was the Dawn interplanetary probe which is currently approximately 93 million miles from Earth and recently entered the asteroid belt between Mars and Jupiter en-route to its 2011 rendezvous with the asteroid Vesta. 

Back here on Earth, Orbital Vice Chairman, President and Chief Operating Officer J.R. Thompson, and Bart Reijnen, Chief Executive Officer of Dutch Space officially signed the Cygnus solar array contract at Orbital’s, Dulles, Virginia headquarters as representatives of Dutch Space, the Netherlands Space Office and Orbital looked on. Mr. Reijnen also presented a commemorative delft plate depicting Cygnus approaching the International Space Station to Orbital Chairman and CEO, David Thompson.  How cool is that?

Progress Continues in the Development of Cygnus and the COTS System

October 2009

The past few months have seen a flurry of preliminary and critical design reviews (PDRs and CDRs) as we begin the transition from the design phase to initial manufacturing.  Several key reviews remain while machining and tooling for the first pressurized cargo modules has begun (see photos below). 

As the year comes to a close, a number of key activities are scheduled to occur including:

• Avionics CDR
• Cygnus CDR
• TAS-I Hatch Review
• Proximity Link System (PLS) CDR and JAXA TIM

We awarded a contract to the Mitsubishi Electric Corp. (MELCO) to supply Proximity Link System (PLS) components to guide Orbital's Cygnus Spacecraft to the International Space Station (ISS) on nine re-supply missions for NASA.

The PLS components were originally developed for the H-II Transfer Vehicle (HTV) program by Mitsubishi Electric under contract with the Japan Aerospace Exploration Agency (JAXA). See the September entry below to read more about Japan’s recent HTV mission to the ISS.

The PLS components, composed of transponders, diplexers, and data handling processors, are essential for rendezvous control between re-supply spacecraft and the ISS. When the re-supply spacecraft approaches the ISS, the on-board PLS initiates a signaling exchange with the PROX (Proximity Communication System), which is built into the ISS as a part of the Japanese Kibo Experimental Module, and guides the spacecraft in rendezvous and berthing with the ISS.

The development and manufacture of the PLS components will be carried out at Mitsubishi Electric's factory in Kamakura, Japan. Mitsubishi Electric will deliver the PLS components to Orbital between 2010 and 2014.

Japanese HTV Successfully Demonstrates Technologies to be Employed by Cygnus, Phase II Safety Review Nears Completion

September 2009

We watched attentively as JAXA’s HII Transfer Vehicle (HTV) successfully performed a rendezvous and berthing with the ISS on September 17, 2009.  The HTV is designed to provide internal and external cargo to the ISS.  The HTV and Cygnus share several systems in common including the Space Integrated GPS/INS (SIGI), Light Detection and Ranging (LIDAR) system, and the Proximity Link System (PLS).  These systems provided vital guidance and navigation information to the spacecraft.   They worked well during the HTV Flight and their performance reduces program risk for Cygnus.  We congratulate Japan for its success in its first HTV flight!

Also this month we presented our Phase II documentation to Johnson Space Center’s Safety Review Panel (SRP) during a weeklong meeting.  The SRP ensures that all appropriate safety requirements are met by spacecraft that carry astronauts (such as the Space Shuttle) or come in close contact with spacecraft that do carry astronauts (such as the International Space Station).  The Safety Review process for human spaceflight is a 3 step process, which involves an extensive review of almost all design elements of the proposed spacecraft.  Orbital passed the first part (Phase I) of the Safety Review process earlier in 2009.  Orbital will close out its Phase II presentation on November 5, 2009.

Pressurized Cargo Module CDR Successfully Completed

August 2009

Last month it was Paris, this time it was on to Torino Italy for the Critical Design Review of the Cygnus Pressurized Cargo Module (PCM) that, mated to our new Cygnus spacecraft, will deliver supplies to the International Space Station. The CDR was a joint effort between Orbital and Thales Alenia Space Italia, which is providing the PCM.  The pressurized cargo module is based on the Multi-Purpose Logistics Module (MPLM) developed by Thales Alenia Space for NASA to ferry cargo to the ISS using the Space Shuttle.
The CDR included two Cygnus PCM configurations. A standard configuration will carry up to 2,000 kg of cargo for the ISS, and will be used in the COTS demonstration mission in 2011 and the first two missions under the Cargo Resupply Services (CRS) contract between 2011 and 2012. An enhanced configuration will carry up to 2,700 kg of cargo for CRS missions between 2013 and 2015.
The CDR demonstrated that the PCM design is ready to proceed with full-scale fabrication, assembly, integration and test of the modules. The CDR also confirmed that the program is on track to complete the development of the Cygnus flight and ground system and mission operations to meet the program’s mission performance requirements. The Pressurized Cargo Module is now moving forward into the production phase to support the COTS demonstration mission slated for March 2011.

Contracts Signed for Cygnus Structure
and Pressurized Cargo Modules

July, 2009

We went to the Paris air show to announce the award of a contract to Thales/Alenia Space of Turin, Italy to build nine pressurized cargo modules that will deliver supplies to the International Space Station (ISS) beginning in 2011.  Also, last month we signed a contract with Applied Aerospace Structures of Stockton, California to provide the composite structures for the Cygnus service module.  In addition to these major contracts, we placed orders for all of major subsystems as we move forward toward actual integration of Cygnus at our Satellite Manufacturing Facility here at Dulles, Virginia.

      Milestones

• Cargo Integration Demonstration successfully completed
• Authorization to Proceed and Long Lead Authorization for CRS Mission 3
• Authorization to Proceed and Long Lead Authorization for CRS Mission 2
• Vehicle Baseline Review for CRS Mission 1
• Authorization to Proceed and Long Lead Authorization for CRS Mission 1
• Authorization to Proceed for Cargo on the COTS Mission
• COTS Mission Proximity Location System Delivery
• PCM Proof Pressure Test
• Service Module Structure Test Readiness Review
• Phase II Safety Review Panel
• COTS Mission CDR
• Pressurized Cargo Module CDR
• Avionics Test Milestone
• Propellant Tank PDR
• Wallops Flight Facility Ground Breaking
• Program Plan Review
• Demo Mission SRR
• COTS Integration/Operations Wallops Flight Facility Review
• Pressurized Cargo Module PDR
• Instrumentation Program and Command List
• ISS Phase 1 Safety Review
• COTS System PDR

      Check Out