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Dream Chaser
Sierra Space Dream Chaser at NASA’s Neil Armstrong Test Facility in 2024
Dream Chaser Tenacity at NASA’s Neil Armstrong Test Facility in 2024
ManufacturerSierra Space
Country of originUnited States
OperatorNASA
ApplicationsInternational Space Station (ISS) resupply
Specifications
Spacecraft typeRobotic cargo vehicle version, also
Crewed orbital spaceplane version
Payload capacity5,000 kg (11,000 lb) pressurized, 500 kg (1,100 lb) unpressurized
Crew capacity
  • 0 (cargo)
  • 3–7 (crew)
RegimeLEO
Production
StatusActive
Built3
Launched0 (4 atmospheric tests)
Operational1
Related spacecraft
Derived fromHL-20 Personnel Launch System
Launch vehicleVulcan Centaur
Dream Chaser flight test vehicle in 2013

Dream Chaser is an American reusable lifting-body spaceplane developed by Sierra Space. Conceived as a crewed vehicle, it is being developed in a cargo configuration known as the Dream Chaser Cargo System for missions to the International Space Station (ISS) under NASA's Commercial Resupply Services program.[1]

Development of Dream Chaser began in 2004 as a project of SpaceDev, which was acquired by Sierra Nevada Corporation (SNC) in 2008.[2] In 2021, the program was transferred to Sierra Space, a subsidiary spun off from SNC as an independent company.

Dream Chaser is designed for vertical takeoff and horizontal landing, launching atop a Vulcan Centaur rocket and landing on conventional runways.[3][4] It is capable of carrying both pressurized and unpressurized cargo. A proposed variant for the European Space Agency would launch aboard an Ariane 6 rocket. The first flight of Dream Chaser was originally scheduled for the second flight of Vulcan Centaur but was not ready in time. As of September 2025, the spacecraft's propulsion system and software had not yet been certified by NASA,[5] and the spacecraft's initial mission in late 2026 will no longer dock at the ISS as originally planned.[6]

The Dream Chaser’s design is derived from NASA's HL-20 Personnel Launch System, a lifting-body concept studied in the 1980s and 1990s.

Spacecraft

[edit]
Dream Chaser engineering test article, being driven along the runway by a pickup truck after an atmospheric test

The Dream Chaser spaceplane is designed to be launched on the top of a typical rocket and land like an airplane on a runway. The design has heritage going back decades. Currently, the Dream Chaser will resupply the ISS with cargo. Per the company's website, a crew version is planned for a later date.

Sierra Space was contracted under CRS-2 to perform resupply missions to the ISS, but in a September 2025 contract change Sierra Space only needs to perform a free flight demonstration, with NASA optionally booking resupply missions.[7][8]

Propulsion

[edit]

On-orbit propulsion of the Dream Chaser was originally proposed to be provided by twin hybrid rocket engines capable of repeated starts and throttling. At the time, the SSC's predecessor, the SNC was also developing a similar hybrid rocket for Virgin Galactic's SpaceShipTwo.[9] In May 2014, SNC involvement in the SpaceShipTwo program ended.[10]

After the acquisition of Orbitec LLC in July 2014, Sierra Nevada Corporation announced a major change to the propulsion system. The hybrid rocket engine design was dropped in favor of a cluster of Orbitec's Vortex engines. The new unit would be a pressure-fed three-mode engine. At low- and mid-power regimes it uses monopropellant fuel – hydrogen peroxide – and in high-power demand, the engine adds injection of RP-1 fuel. This increased thrust will be useful to shorten the de-orbit burn duration of the Dream Chaser.[11]

Thermal protection system

[edit]

Its thermal protection system (TPS) is made up of silica-based tiles (for most of the belly and upper portion of the heat shield), and a new composite material called Toughened Unipiece Fibrous Reusable Oxidation Resistant Ceramic (TUFROC) to cover the nose and leading edges.[12][13]

Shooting Star module

[edit]

In 2019, it was announced that an expendable Shooting Star cargo module would be part of the Dream Chaser cargo system for CRS-2 flights.[14][15][16] The module is a 15-foot-long (4.6 m) attachment to Dream Chaser that will allow the spacecraft to carry an additional 10,000 pounds (4,500 kg) of pressurized and unpressurized cargo to ISS. The module supports disposal of unwanted cargo by burning up upon re-entry.

In addition to carrying cargo, the Shooting Star module includes solar panels that supply up to 6 kW of electrical power. It also supplies active and passive thermal management; provides Dream Chaser translation and rotation capability via six mounted thrusters; and supports berthing or docking (in different configurations) to the ISS. Access from ISS to Dream Chaser will involve crew passing through Shooting Star (which supports a shirt-sleeve environment) and through a hatch that separates Shooting Star from Dream Chaser. Sierra Nevada says the module is capable of additional types of missions in LEO or to cis-lunar destinations; they have developed a free-flying variant with additional capabilities.[17]

In July 2020, Sierra Nevada announced a contract with the Defense Innovation Unit (DIU) to use its Shooting Star expendable cargo vehicle as a possible commercial solution for a high-powered uncrewed orbital outpost.[18]

Technology partners

[edit]

In 2010, the following organizations were named as technology partners for the original passenger Dream Chaser:[19]

History

[edit]
Men stand next to a sleek, black spaceplane.
Prototype of the X-20 Dyna Soar - a spacecraft the Dream Chaser spaceplane is based on

The Dream Chaser design is derived from NASA's HL-20 Personnel Launch System spaceplane concept,[2][22] which in turn is descended from a series of test vehicles, including the X-20 Dyna-Soar, Northrop M2-F2, Northrop M2-F3, Northrop HL-10, Martin X-24A and X-24B,[23][24][25] and Martin X-23 PRIME.[26]

The name "Dream Chaser" had been previously used for two separate space vehicle concepts. The first was planned to be an orbital vehicle based on the HL-20, with the second suborbital vehicle proposed by the Benson Space Company for the purposes of space tourism.[27]

The Dream Chaser was publicly announced on September 20, 2004.[28] In April 2007, SpaceDev announced that it had partnered with the United Launch Alliance to pursue the possibility of using the Atlas V booster rocket as the Dream Chaser's launch vehicle.[29] In June 2007, SpaceDev signed a Space Act agreement with NASA.[30]

On October 21, 2008, SpaceDev with Dream Chaser was acquired by the Sierra Nevada Corporation for US$38 million.[31]

CCDev phase 1

[edit]

On February 1, 2010, Sierra Nevada Corporation was awarded $20 million in seed money under NASA's Commercial Crew Development (CCDev) phase 1 program for the development of the Dream Chaser.[32][33] SNC completed the four planned milestones on time, including hybrid rocket test fires and the preliminary structure design.[34] Further initial Dream Chaser tests included the drop test of a 15% scaled version at the NASA Dryden Flight Research Center.[35]

CCDev phase 2

[edit]

Sierra Nevada proposed Dream Chaser for the CCDev phase 2 solicitation by NASA in October 2010, with an estimated project cost of less than $1 billion.[36][37] On 18 April 2011, NASA awarded $80 million to Sierra Nevada Corporation for Dream Chaser.[38] Since then, nearly a dozen further milestones have been completed under that Space Act Agreement. Some of these milestones included testing of an improved airfoil fin shape, integrated flight software and hardware, landing gear, a full-scale captive carry flight test, and a Systems Requirement Review (SRR).[39][40]

By February 2012, Sierra Nevada Corporation stated that it had completed the assembly and delivery of the primary structure of the first Dream Chaser flight test vehicle. With this, SNC completed all 11 of its CCDev milestones that were scheduled up to that point. SNC stated in a press release that it was "on time and on budget."[41]

On May 29, 2012, the Dream Chaser Engineering Test Article (ETA) was lifted by an Erickson Skycrane helicopter in a captive carry test to better determine its aerodynamic properties.[42][43] In May 2013, the ETA was shipped to the Dryden Flight Research Center in California for a series of ground tests and aerodynamic flight tests.[44] A second captive carry flight test was completed on August 22, 2013.[45]

On June 12, 2012, SNC announced the commemoration of its fifth year as a NASA Langley partner in the design and development of Dream Chaser.[46] The NASA/SNC team had worked on aerodynamic and aerothermal analysis of Dream Chaser, as well as guidance, navigation, and control systems. Together with ULA, the NASA/SNC team performed buffet tests on the Dream Chaser and Atlas V stack.[46]

On July 11, 2012, SNC announced that it successfully completed testing of the nose landing gear for Dream Chaser.[47] This milestone evaluated the impact to the landing gear during simulated approach and landing tests as well as the impact of future orbital flights. The main landing gear was tested in a similar way in February 2012. The nose gear landing test was the last milestone to be completed before the free flight approach and landing tests scheduled for later in 2012.[47] In August 2012, SNC completed CCiCap Milestone 1, or the 'Program Implementation Plan Review'. This included creating a plan for implementing design, development, testing, and evaluation activities through the duration of CCiCap funding.[48] By October 2012 the "Integrated System Baseline Review", or CCiCap Milestone 2, had been completed. This review demonstrated the maturity of the Dream Chaser Space System as well as the integration and support of the Atlas V launch vehicle, mission systems, and ground systems.[48]

CCiCap

[edit]

On August 3, 2012, NASA announced the award of $212.5 million to Sierra Nevada Corporation to continue work on the Dream Chaser under the Commercial Crew Integrated Capability (CCiCap) Program.[49] On January 30, 2013, SNC announced a new partnership with Lockheed Martin. Under the agreement, SNC will pay Lockheed Martin $10 million to build the second airframe at its Michoud facility in New Orleans, Louisiana. This second airframe is slated to be the first orbital test vehicle, with orbital flight testing planned to begin within the next two years.[20]

In January 2013, Sierra Nevada announced that the second captive carry and first unpowered drop test of Dream Chaser would take place at Edwards Air Force Base, California in March 2013. The spaceplane release would occur at 12,000 feet (3,700 m) altitude and would be followed by an autonomous robotic landing.[20][21]

On March 13, 2013, NASA announced that former Space Shuttle commander Lee Archambault was leaving the agency in order to join SNC. Archambault, a former combat pilot and 15-year NASA veteran who flew on Atlantis and Discovery, will work on the Dream Chaser program as a systems engineer and test pilot.[50][51]

On October 26, 2013, the first free-flight occurred. The test vehicle was released from the helicopter and flew the correct flightpath to touchdown less than a minute later. Just prior to landing, the left main landing gear failed to deploy resulting in a crash landing.[52] The vehicle skidded off the runway in a cloud of dust, but was found upright with the crew compartment intact and all systems inside still in working order.[53][54]

In January 2014, SNC announced it had signed a launch contract to fly the first orbital test vehicle on a robotically controlled orbital test flight in November 2016.[55]

Dream Chaser model being tested at NASA Langley, aboard an Atlas V mock-up

In early 2014, Sierra Nevada completed its wind tunnel testing as part of its CCiCAP Milestone 8. The wind tunnel testing involved analyzing the flight dynamics characteristics that the vehicle will experience during orbital ascent and re-entry. Wind tunnel testing was also completed for the Dream Chaser Atlas V integrated launch system. These tests were completed at NASA Ames Research Center at Moffett Field, California, CALSPAN Transonic Wind Tunnel in New York, and at NASA Langley Research Center Unitary Plan Wind Tunnel in Hampton, Virginia.[56]

On August 1, 2014, the first completed piece of the orbital Flight Test Article (FTA) composite airframe was unveiled at a Lockheed Martin facility.[57]

CCtCap

[edit]

On September 16, 2014, NASA did not select the Dream Chaser for CCtCap, the next phase of the Commercial Crew Program. This occurred despite previous Commercial Crew Development awards in every phase since 2009,[58] due to lack of maturity.[59]

On September 26, Sierra Nevada filed a protest to the US Government Accountability Office (GAO).[60] On October 22, 2014, a Federal Judge ruled the contract awards to Boeing and SpaceX valid, allowing NASA to proceed.[61]

On September 29, 2014, Sierra Nevada introduced the "Dream Chaser Global Project" which would provide customized access to low Earth orbit to global customers.[62]

Despite not being selected to continue forward under NASA's Commercial Crew transportation Capability (CCtCap) phase of the effort to send crews to orbit via private companies, SNC completed the milestones assigned under earlier phases of the CCP.[63] On December 2, 2014, SNC announced that it completed NASA's CCiCap Milestone 5a related to propulsion risk reduction for the Dream Chaser space system.[64]

By late December, details had emerged that "a high-ranking agency official"—"William Gerstenmaier, the agency's top human exploration official and the one who made the final decision"—"opted to rank Boeing's proposal higher than a previous panel of agency procurement experts." More specifically, Sierra Nevada asserted in their filings with the GAO that Gerstenmaier may have "overstepped his authority by unilaterally changing the scoring criteria."[65]

On January 5, 2015, the GAO denied Sierra Nevada's CCtCap challenge, stating that NASA made the proper decision when it decided to award Boeing $4.2 billion and SpaceX $2.6 billion to develop their vehicles. Ralph White, the GAO's managing associate counsel, announced that NASA "recognized Boeing's higher price but also considered Boeing's proposal to be the strongest of all three proposals in terms of technical approach, management approach and past performance, and to offer the crew transportation system with most utility and highest value to the government."[66] Furthermore, the agency found "several favorable features" in SNC's proposal "but ultimately concluded that SpaceX's lower price made it a better value."[66]

CRS-2 selection

[edit]
Further information: Commercial Resupply Services

In December 2014, Sierra Nevada proposed Dream Chaser for CRS-2 consideration.[67] In January 2016, NASA announced that Dream Chaser had been awarded one of the CRS-2 contracts and committed to purchasing a minimum of six resupply missions to the ISS.[68] The cargo spacecraft will fly alongside spacecraft from the existing CRS-1 contract holders SpaceX and Northrop Grumman Innovation Systems.[69]

In October 2015, the thermal protection system was installed on the Engineering Test Article (ETA) for the next phase of atmospheric flight testing. The orbital cabin assembly of the Flight Test Article (FTA) was also completed by contractor Lockheed Martin.[70]

In 2015, the ETA had reportedly been given the name Eagle,[44] while the FTA was originally named Ascalon before being changed to Ascension.[71]

On November 11, 2017, the Dream Chaser ETA was released from an altitude of 3,700 m and successfully landed at Edwards AFB.[72][73]

In March 2019, completion of NASA's Integrated Review Milestone 5 (IR5) confirmed that development was still on schedule.[74][75] In August 2019, SNC announced the first ISS flight of the Dream Chaser, known as SNC Demo-1, was planned for 2021.[3] However, on November 17, 2020, SNC announced it would be delayed until early 2022.[76]

In April 2021 SNC spun off its Dream Chaser division, creating the fully independent Sierra Space Corporation, which assumed responsibility for the further development of the Dream Chaser space vehicle system.

In May 2022, it was announced by the deputy manager of ISS, Dana Weigel, that the mission was scheduled for February 2023.[77]

In May 2024, it was announced that Dream Chaser Tenacity completed initial flight testing and was headed next to Kennedy Space Center to prepare for launch.[78] It arrived later that month for launch preparation.[79] The Vulcan Centaur to be used for the launch arrived to KSC in late June 2024. However, the Orlando Sentinel reports, June 26, "Dream Chaser dropped from next Vulcan launch as ULA targets national security certification". The mission was subsequently delayed to no earlier than May 2025, and had still not been scheduled for a specific date as of September 2025.[80]

In September 2025, NASA announced that Dream Chaser's demonstration flight, SSC Demo-1, will no longer visit the ISS and was delayed to late 2026.[6] The spacecraft is also no longer contracted to complete seven resupply missions to the ISS.[81]

Variants

[edit]

Crewed version

[edit]
Artist's conception of the Dream Chaser Space System in the launch configuration of the Atlas V

The originally planned Dream Chaser Space System is a human-rated version designed to carry from three to seven people and cargo to orbital destinations such as the International Space Station.[82] It was to have a built-in launch escape system[9] and could fly autonomously if needed.[83] Although it could use any suitable launch vehicle, it was planned to be launched on a human-rated Atlas V N12 rocket.[83][84] The vehicle will be able to return from space by gliding (typically experiencing less than 1.5 g on re-entry) and landing on any airport runway that handles commercial air traffic.[85][19] Its reaction control system thrusters burned ethanol-based fuel,[83][85] which is not an explosively volatile material, nor toxic like hydrazine, allowing the Dream Chaser to be handled immediately after landing, unlike the Space Shuttle.[83]

As of 2020, the Sierra Nevada Corporation said it still planned to produce a crewed version of the spacecraft within the next 5 years. The company said it "never stopped working" on the crewed version and fully intended to launch it after the cargo version,[86] and is still committed to the crewed version as of 2021.[87]

In November 2021, Sierra Space Corporation reported that it received a $1.4 billion investment in Series A funding, which it would use to develop a crewed version of Dream Chaser and fly astronauts by 2025, although this ultimately did not occur.[88] On October 25, 2021, Blue Origin and Sierra Space, released their plan for a commercial space station.[89] The station, called Orbital Reef, is intended as a "mixed-use business park".[90] Sierra Space Corporation's Dream Chaser was chosen as one of the commercial spacecraft to transport commercial crew to and from the space station, along with Boeing's Starliner.[91]

CRS-2 cargo version

[edit]
Artist's conception of the crewed Dream Chaser docked to International Space Station

The cargo version of the SSC Dream Chaser is called the Dream Chaser Cargo System (DCCS) and after development is completed, will fly resupply flights to the ISS under NASA's Commercial Resupply Services-2 program. Featuring an expendable cargo module mounting solar panels, the spacecraft will be capable of returning 1,750 kg (3,860 lb) to Earth while undergoing maximum re-entry forces of 1.5G.[92][93]

To meet CRS-2 guidelines, the cargo Dream Chaser will have folding wings and fit within a 5 m diameter payload fairing, in contrast to the Crewed Dream Chaser, which is intended to launch without a fairing. The ability to fit into a payload fairing allows the cargo version to launch on any sufficiently capable vehicle, such as the (retired) Ariane 5 as well as the (soon to be retired) Atlas V. An expendable cargo module will launch attached to the back of the spacecraft, expanding the cargo uplift capacity and supporting the disposal of up to 3,250 kg (7,170 lb) of trash. Total uplift is planned for 5,000 kg (11,000 lb) pressurized and 500 kg (1,100 lb) unpressurized, with a downlift of 1,750 kg (3,860 lb) contained within the spaceplane.[94] The expendable cargo module is called "Shooting Star".[95]

On August 14, 2019, it was announced that all six Dream Chaser CRS-2 flights would be carried into orbit by ULA's Vulcan launch vehicle, with the first Dream Chaser flight being the second Vulcan flight in late 2021.[3][96] However, on February 9, 2022, Ken Shields, Sierra Space's Director of Commercial Market Development, announced that the first flight would be pushed to January 2023.[97] The launch has been further delayed; as of October 2024, it is scheduled for no earlier than May 2025.[80][needs update]

National Security version

[edit]

On November 19, 2021, Sierra Space announced that it is considering a third Dream Chaser version specialized for National Security missions, though it declined to comment on what the differences compared with other versions would be.[98]

Dream Chaser Global Project

[edit]

In December 2013, the German Aerospace Center (DLR) announced a funded study to investigate ways in which Europe might take advantage of the Dream Chaser crewed spaceplane technology. Named the DC4EU (Dream Chaser for European Utilization), the project will study using it for sending crews and cargo to the ISS and on missions not involving the ISS, particularly in orbits of substantially greater altitude than the ISS can reach.[99]

In January 2014, the European Space Agency (ESA) agreed to be a partner on the DC4EU project, and will also investigate whether the Dream Chaser can use ESA avionics and docking mechanisms. ESA will also study launching options for the "Europeanized" Dream Chaser, particularly whether it can be launched from the Guiana Space Centre, within the Ariane 5's large aerodynamic cargo fairing – or, like the Atlas V, without it. In order to fit within the fairing, the Dream Chaser's wing length will have to be reduced slightly, which is thought to be easier than going through a full aerodynamic test program to evaluate and prove it along with the Ariane for flight without the fairing.[100] The Ariane 5 launch vehicle was designed from its inception to be crew rated, in order to launch the Hermes Spaceplane, an ESA crewed vehicle which was proposed in the 1980s and 1990s, but was cancelled.

In late January 2014, it was announced that the Dream Chaser orbital test vehicle was under contract to be launched on an initial orbital test flight, using an Atlas V rocket, from Kennedy Space Center in November 2016. This was a privately arranged commercial agreement, and was funded directly by Sierra Nevada and was not a part of any existing NASA contract.[55]

In September 2014, SNC announced that it would, with global partners, use the Dream Chaser as the baseline spacecraft for orbital access for a variety of programs, specializing the craft as needed.[101]

On November 5, 2014, SNC's Space Systems team publicly presented the challenges and opportunities related to landing the Dream Chaser spacecraft at public-use airports.[102] Dream Chaser uses standard landing aids and non-toxic propellants that require no special handling.[103]

Dream Chaser for European Utilization

[edit]

On February 3, 2015, the Sierra Nevada Corporation's (SNC) Space Systems and OHB System AG (OHB) in Germany announced the completion of the initial Dream Chaser for European Utilization (DC4EU) study.[104] The study found that Dream Chaser is suitable for a broad range of space applications and could be used to advance European interests in space.[105] The cooperation was renewed in April 2015 for an additional two years.[105] [needs update]

United Nations

[edit]

The United Nations Office for Outer Space Affairs (UNOOSA) selected the cargo Dream Chaser for its first space launch. This launch is intended to last for at least two weeks in freeflight to provide space access to United Nations member states that have no space programs of their own, and carry up to 35 payloads.[106] The United States will pay for the mission and provide all support facilities.[107]

List of vehicles

[edit]
  Test vehicle   Spaceflight vehicle
Type Serial Name Status Flights Time in flight Notes
Prototype ETA Eagle Retired 4 ~5 minutes Engineering Test Article (ETA) used for captive carry and atmospheric drop tests
Prototype FTA Ascension Active 0 None Flight Test Article (FTA) to be used for atmospheric tests
Cargo DC101[108] Tenacity Active[109] 0 None Spacecraft to be flown on SSC Demo-1 mission.
Cargo DC102 Reverence Under construction 0 None Construction on hold as of November 2024; company estimates 18 months of work remain.[110][111]

Mockups

[edit]
Name Location Status Notes
Dream Chaser[112] Wings Over the Rockies Air and Space Museum On Display Replica of a crewed Dream Chaser spaceplane. Originally constructed in 1990 as an HL-20 mockup prior to the program's cancellation.
Tenacity[113] Kennedy Space Center Visitor Complex On Display Replica of Tenacity mated to Shooting Star module. Located in Gateway section of the complex.

Missions

[edit]

A demonstration and six missions are currently planned to be launched from Cape Canaveral SLC-41 on Vulcan Centaur, and one more flight has been ordered to fly for the United Nations on board an Arianespace vehicle.[citation needed]

List includes only completed or manifested missions. NET means 'no earlier than'. Launch and landing dates and times are listed in UTC.

Mission Spacecraft Launch Landing Launch vehicle Remarks Outcome
Captive Test 1 ETA Eagle May 29, 2012 May 29, 2012 Erickson Skycrane[a] 1st atmospheric test Success
Captive Test 2 ETA Eagle August 22, 2013 August 22, 2013 Erickson Skycrane[a] 2nd atmospheric test Success
Drop Test 1 ETA Eagle October 26, 2013 October 26, 2013 Erickson Skycrane[a] 1st free flight test Partial success
Drop Test 2 ETA Eagle November 11, 2017 November 11, 2017 Boeing-Vertol 234[a] 2nd free flight test Success
SSC Demo-1 DC101 Tenacity NET Late 2026 NET Late 2026 Vulcan Centaur First orbital flight, originally a ~45 days duration ISS resupply mission, now will not visit the ISS. Planned
CRS SSC-1 DC101 Tenacity TBA TBA Vulcan Centaur 1st contracted CRS mission for NASA Cancelled
CRS SSC-2 DC101 Tenacity TBA TBA Vulcan Centaur 2nd contracted CRS mission for NASA Cancelled
CRS SSC-3 DC101 Tenacity TBA TBA Vulcan Centaur 3rd contracted CRS mission for NASA Cancelled
CRS SSC-4 DC102 Reverence[114] TBA TBA Vulcan Centaur 4th contracted CRS mission for NASA Cancelled
CRS SSC-5 TBA TBA TBA Vulcan Centaur 5th contracted CRS mission for NASA Cancelled
CRS SSC-6 TBA TBA TBA Vulcan Centaur 6th contracted CRS mission for NASA Cancelled
DC UNOOSA-1 TBA TBA TBA Arianespace vehicle To carry 35 payloads for the United Nations Office for Outer Space Affairs.[106] Planned
  1. ^ a b c d A helicopter used for lifting the vehicle

See also

[edit]

Spaceplanes

Other ISS cargo vehicles:

Other ISS crew vehicles:

References

[edit]
[edit]
Revisions and contributorsEdit on WikipediaRead on Wikipedia

Dream Chaser

View on Grokipedia
from Grokipedia
The Dream Chaser is a reusable, uncrewed lifting-body developed by to transport to and from , including resupply missions to the (ISS) under 's Commercial Resupply Services-2 (CRS-2) contract. The spacecraft features a compact winged design measuring approximately 30 feet (9 meters) in length with a of 23 feet (7 meters), enabling it to launch vertically atop a rocket and perform an autonomous horizontal glide landing on conventional runways worldwide, similar to an . Paired with its Shooting Star module, Dream Chaser can deliver up to 5,200 kilograms (11,500 pounds) of pressurized and unpressurized to the ISS while returning up to 1,600 kilograms (3,500 pounds) of to Earth. Development of Dream Chaser traces its roots to NASA's concept from the 1990s, which refined into a modern vehicle starting in the mid-2000s after acquiring SpaceDev in 2008. Initially proposed as a crewed under NASA's Commercial Crew Development (CCDev) program, where it received funding milestones in 2010 and 2011, the design shifted to an uncrewed cargo configuration following NASA's 2014 selection of competitors and for crewed transportation. In 2016, secured a CRS-2 for a minimum of six resupply missions to the ISS as part of NASA's overall CRS-2 program with a total ceiling of up to $14 billion across all providers, positioning Dream Chaser as the only runway-landing vehicle in NASA's commercial cargo fleet. The first operational vehicle, named Tenacity, integrates the Dream Chaser spaceplane atop the expendable Shooting Star module, which provides additional cargo volume, generation, and propulsion for orbital maneuvers using a bipropellant system. Tenacity's systems include reaction control thrusters for precise attitude control in space and a low-g reentry profile to protect sensitive payloads, with the ability to remain docked at the ISS for up to 75 days per mission. As of September 2025, and modified the CRS-2 contract to convert Tenacity's debut flight into a free-flyer demonstration without ISS docking, due to ongoing development challenges, with launch now targeted no earlier than late 2026 aboard a from . This adjustment allows focus on vehicle certification while preserving future docking capabilities for subsequent missions. Beyond ISS resupply, Dream Chaser's versatile design supports multi-mission applications, including satellite deployment, in-orbit refueling, and potential crewed variants for point-to-point transport or operations, with planning a fleet of up to 15 reusable vehicles. The program has undergone extensive testing, including vibration, acoustics, and free-flight drop tests at , demonstrating its robustness for repeated use up to 15 times per vehicle.

Design

Configuration

The Dream Chaser employs a lifting-body design derived from NASA's concept, utilizing a wingless, blended-body configuration that generates lift during atmospheric reentry without traditional wings, facilitating unpowered gliding and precise horizontal landings on conventional runways. This architecture prioritizes aerodynamic efficiency for orbital return, allowing the to autonomously deorbit and maneuver through the atmosphere like a glider. The vehicle's physical dimensions are 9 m in length, 4.5 m in width (with wings folded for launch), and 1.3 m in height, enabling compact integration atop launch vehicles such as the while supporting a pressurized capacity of up to 1,750 kg. These proportions contribute to its overall gross mass of approximately 9,000 kg, balancing volume with structural integrity for reusability across multiple missions. Aerodynamically, the Dream Chaser incorporates a blunt to manage high-speed reentry heating and plasma formation, paired with a flat bottom that enhances hypersonic stability and during descent. Control is achieved through specialized surfaces, including split rudders for yaw and speed braking, ailerons for roll, and a deployable speed to modulate descent velocity and enable steep approaches. During reentry, the spacecraft follows an autonomous glide profile from low Earth orbit, leveraging its lifting-body shape to perform a controlled, unpowered descent culminating in a shuttle-like runway landing, with a cross-range capability exceeding 1,500 km for flexible site selection worldwide. This profile maintains peak loads below 1.5 g, prioritizing safe recovery and rapid post-landing turnaround. The payload bay accommodates both pressurized and unpressurized cargo through standard interfaces such as the and common berthing mechanisms. This modular volume supports diverse payloads, from scientific experiments to resupply items, with provisions for rapid integration and extraction upon return.

Propulsion

The Dream Chaser relies on its , such as the , for initial orbital insertion to . Onboard propulsion systems enable rendezvous with targets like the , attitude control, and the deorbit burn required for reentry and runway landing. The spacecraft's (RCS) features 26 thrusters distributed across the vehicle and its Shooting Star cargo module for precise maneuvering in and during reentry. These thrusters, developed under Sierra Space's VORTEX engine family, operate in three discrete modes to support fine attitude adjustments and larger burns as needed. Low- and medium- modes (approximately 40 lbf and 60 lbf, respectively) use (HTP) as a monopropellant for efficient, low-power control, while the high- mode (approximately 110 lbf) injects (refined ) for bipropellant operation, enhancing performance during critical phases like rendezvous and deorbit. The non-toxic HTP/ propellant combination allows safe ground handling and rapid post-landing cargo access without hazardous material protocols. The module contributes to the overall by housing tanks and six aft-pointing thrusters, which perform the primary deorbit burn after separation from the , enabling the module to reenter and dispose of waste cargo. storage in the module supports mission durations in , with the system integrated for seamless operation between the and module. The components are engineered for high reusability, targeting more than 15 flights per with routine post-flight inspections and minimal refurbishment to ensure reliability and cost efficiency across multiple missions.

Thermal Protection

The thermal protection system (TPS) of the Dream Chaser primarily utilizes silica-based tiles, inspired by those employed on the , to shield the from the intense encountered during atmospheric reentry. These non-ablative tiles cover approximately 95% of the 's exterior surface, providing robust insulation without material loss, while quilted blankets made from silica fibers are applied to the upper surfaces that experience lower heat loads. Designed for hypersonic reentry at speeds up to Mach 25, the TPS withstands peak surface temperatures of 1,650°C, ensuring structural integrity and protecting internal components from thermal damage. The underside, or belly, features denser ceramic tiles in areas of highest to handle the concentrated plasma heating during the vehicle's gliding descent. This configuration supports the spaceplane's reusability, with the tiles being removable for post-flight inspection and refurbishment, allowing the same TPS to endure a minimum of 15 flights without replacement. Validation of the TPS performance has involved extensive ground testing, including wind tunnel simulations to assess aerodynamic heating profiles and arc jet facility exposures at NASA's to replicate reentry plasma environments. These tests, conducted from initial development through 2025, confirmed the materials' ability to maintain thermal barriers under repeated hypersonic conditions, with advancements as of November 2024 incorporating carbon fiber-reinforced silicon-carbide (C/SiC) composites for enhanced durability on future vehicles.

Shooting Star Module

The Shooting Star Module is a disposable cylindrical service and module developed by for attachment to the aft of the Dream Chaser , enhancing overall mission flexibility by providing dedicated and additional accommodations. Measuring approximately 4.8 meters in length, the module integrates seamlessly with the spaceplane via a light-band interface, allowing it to function as an expendable extension that supports both uncrewed and crewed variants during ascent, on-orbit operations, and deorbit phases. This design enables the Dream Chaser stack to achieve greater efficiency while the module itself is jettisoned and disposed of in Earth's atmosphere post-mission. In terms of cargo capacity, the Shooting Star Module provides an internal cargo volume of up to 3,175 kg (primarily pressurized) and three external mounting points for unpressurized payloads weighing up to 500 kg each. Combined with the Dream Chaser , the system can deliver up to 5,500 kg of mixed pressurized and unpressurized payload to the (ISS) under NASA's Commercial Resupply Services 2 (CRS-2) framework. The pressurized volume features a door compatible with ISS transfer mechanisms, facilitating efficient exchange of supplies, experiments, and waste between the module and station modules without the need for . The itself enables the return of up to 1,750 kg of cargo to . The module's propulsion integration is central to its role, housing the primary engines, propellant tanks, and attitude control thrusters that power the entire Dream Chaser vehicle during key maneuvers, including orbit raising, rendezvous, and separation from the . It performs the critical deorbit burn to set the spaceplane on its reentry trajectory before being separated and allowed to reenter destructively, ensuring safe disposal of any residual cargo or waste. This expendable architecture draws from proven service module concepts, providing up to 6 kW of electrical power via deployable solar arrays and environmental control systems to support extended on-orbit durations. Development of the Shooting Star Module evolved from the Dream Chaser's original integrated cargo and propulsion design, which was reconfigured in the mid-2010s to separate the expendable elements for improved reusability of the and compliance with CRS-2 requirements for cargo disposal. Unveiled in November , the module underwent initial structural testing, including verification of its composite as the first such component certified for ISS visitation. By 2023, it progressed to integrated vibration and environmental testing at NASA's Test Facility, with ongoing certification efforts for CRS-2 missions as of late 2025, paving the way for operational flights beginning in 2026.

Avionics

The suite of the Dream Chaser supports autonomous mission execution, integrating guidance, , control, and communication subsystems to manage operations from orbital insertion through runway landing. Developed by in collaboration with partners like Odyssey Space Research, the flight software encompasses the full mission profile, ensuring compliance with safety and technical standards under the Commercial Resupply Services-2 (CRS-2) contract. The (GNC) system relies on a combination of sensors for precise trajectory management, particularly during reentry and potential rendezvous maneuvers. Star trackers provide high-accuracy attitude determination, serving as a dominant error source mitigator for touchdown precision in autonomous scenarios. This setup enables the vehicle to perform controlled glides and adjustments without ground intervention, as demonstrated in prior free-flight tests at NASA's . Central to the avionics is the fault-tolerant flight computer, featuring a triple-redundant to enhance reliability against single-point failures in the harsh . This design incorporates radiation-tolerant components, including enhanced solid-state recorders for onboard data capture during missions. The system supports fully autonomous reentry and landing at commercial runways, with provisions for or scripted autonomy during docking operations if required. Communication systems facilitate real-time monitoring and data transfer, utilizing S-band links for , tracking, and command with ground stations. For high-data-rate operations, such as potential ISS proximity, Ku-band capabilities enable robust downlink of mission data. As of November 2025, the remains in validation phases, focusing on , cybersecurity, and to achieve full for operational flights, including a recent successful demonstration of and command distribution on November 12, 2025. Recent milestones include environmental testing and simulation runs with , though propulsion and software delays have pushed the debut free-flyer mission to late 2026.

Development

Origins

The Dream Chaser spaceplane traces its origins to the mid-2000s, when SpaceDev revived NASA's design—a lifting-body concept studied at in the —as the basis for a reusable vehicle capable of carrying crew and cargo to destinations like the . Following SpaceDev's acquisition by (SNC) in 2008, the project was rebranded Dream Chaser and advanced as a privately developed emphasizing runway landings for rapid reusability. Early development relied entirely on self-funding from SNC, enabling key milestones such as subscale drop tests conducted from a in 2010, which validated the lifting-body configuration's aerodynamic stability during unpowered flight. By 2010, SNC announced the of a full-scale to support further engineering evaluations, marking a significant step in proving the vehicle's feasibility without government support. The design evolved to enhance cost efficiency, shifting from an integrated propulsion system to a separate aft module—later formalized as —for propulsion and cargo accommodation by 2012, allowing modular upgrades and simplified reusability. Former astronaut Jim Voss served as the program's lead, initially as vice president of SNC's Space Exploration Systems starting in 2008 and overseeing development until his retirement in 2013. This foundational private effort positioned SNC to pursue 's Commercial Crew Development program for further maturation.

Commercial Programs

, formerly known as (SNC), participated in NASA's Commercial Crew Development (CCDev) program starting in 2010, receiving funding to advance the spacecraft from concept to flight demonstrator stages. This involvement focused on developing a reusable capable of transporting crew and cargo to , emphasizing risk reduction and integration with existing launch systems. The program progressed through multiple phases, culminating in a pivot to cargo resupply after crew certification efforts were not selected. In February 2010, under CCDev Phase 1, awarded SNC $20 million to conduct risk reduction studies and prototyping for the Dream Chaser, including development of avionics systems to support autonomous flight operations. This funding enabled early engineering assessments of the lifting-body design's stability, guidance, and control systems, laying the groundwork for subsequent testing. By the end of the phase, SNC had completed key milestones, such as preliminary design reviews that validated the spacecraft's compatibility with the launch vehicle. Building on this, CCDev Phase 2 awarded SNC $80 million in April 2011 to construct and test a flight demonstrator . The funds supported the fabrication of the Dream Chaser Engineering Test Article () and ground-based simulations, progressing toward free-flight capabilities. This phase culminated in a series of drop tests in 2013, where the was released from a B-52 mothership at NASA's Dryden Flight Research Center to evaluate deployment and aerodynamic performance, despite a minor gear failure in one test that provided valuable data for refinements. NASA's Commercial Crew Integrated Capability (CCiCap) phase, announced in August 2012, provided SNC with $212.5 million to integrate systems into the Dream Chaser, focusing on a seven-seat configuration for missions to the . Key efforts included subscale testing of the launch abort system to ensure safe separation from the during ascent anomalies, as well as pad abort demonstrations simulating emergency scenarios. An additional $15 million in 2013 brought the total CCiCap funding to $227.5 million, supporting further milestones like firings and environmental testing. In the subsequent Commercial Crew Transportation Capability (CCtCap) phase, initiated in , SNC proposed a fully certified crewed Dream Chaser but was not selected for the primary contracts awarded to and , valued at $6.8 billion combined. Although SNC received a minor extension of approximately $14.5 million in related funding to complete outstanding CCiCap work, the decision shifted the company's focus away from immediate crew certification toward cargo applications. SNC protested , citing its competitive pricing and mission suitability, but the challenge was ultimately unsuccessful. Transitioning to cargo operations, selected Dream Chaser for the Commercial Resupply Services 2 (CRS-2) contract in January 2016, awarding SNC an initial task order estimated at around $14 million to begin integration and for uncrewed ISS resupply missions. The broader CRS-2 agreement guaranteed a minimum of seven missions to SNC, with potential expansion to more, carrying an overall program ceiling of $14 billion across providers and enabling up to approximately $1.43 billion in value for Dream Chaser flights based on mission awards. This selection repurposed the vehicle's design for autonomous delivery, leveraging prior development investments.

Recent Milestones

Between 2020 and 2023, the Dream Chaser program advanced through key ground testing phases, including structural assessments and environmental simulations to validate the vehicle's integrity under launch conditions. In December 2023, the and its Shooting Star cargo module underwent and testing at NASA's A. Armstrong Test Facility in , simulating the rigors of and confirming structural resilience. These efforts built on earlier and compatibility (EMI/EMC) evaluations, which were completed by early 2020 as part of NASA's certification requirements for commercial cargo vehicles. Propulsion system validation included hot-fire tests of the VORTEX engines at , demonstrating reliable ignition and thrust performance essential for orbital insertion and reentry maneuvers. In 2024, the program encountered significant delays due to integration challenges with the Vulcan Centaur rocket, originally slated for the vehicle's debut flight in late 2023 or early 2024. These issues, stemming from compatibility testing and supply chain disruptions, postponed the inaugural mission and shifted focus to additional ground verifications. By mid-2024, the vehicle had arrived at NASA's for final assembly and EMI/EMC testing, marking progress toward flight readiness despite the setbacks. A pivotal update occurred in September 2025 when and modified the Commercial Resupply Services-2 (CRS-2) contract, converting the first Dream Chaser mission from an docking to a free-flyer demonstration without ISS berthing. This revision, valued at up to $14 billion across CRS-2 providers, targets a launch no earlier than late 2026 aboard a rocket, allowing to prioritize vehicle certification while accommodating schedule realities. As of November 2025, propulsion systems and flight software remain under review for final approval, with ongoing tests focusing on autonomy and reliability. In November 2025, Dream Chaser completed and compatibility testing at NASA's , as well as tow tests to verify navigation and communication systems. Launch acoustics testing is scheduled for December 2025. The contract changes reflect 's strategic pivot toward defense and private sector applications, positioning Dream Chaser as a versatile platform for missions and commercial payloads beyond ISS resupply. This shift emphasizes multi-use capabilities, including potential integration with alternative launchers. continues collaboration with for future operations.

Variants

Cargo Variant

The cargo variant of Dream Chaser serves as the primary uncrewed configuration for NASA's Commercial Resupply Services 2 (CRS-2) program, focusing on resupply missions to the (ISS). This baseline design enables delivery of up to 5,500 kg of combined pressurized and unpressurized to the ISS, supporting such as , , scientific , and supplies. It also provides a return capability of up to 1,750 kg of pressurized and samples to , with an additional 3,250 kg of waste disposed of via the expendable module during re-entry. Key modifications for operations include a pressurized cabin, offering approximately 33 cubic meters of volume in the system ( and Shooting Star module) for up to 5,000 kg of pressurized upmass and 1,750 kg of return . The nose-mounted (IDSS) port allows direct transfer of to and from the ISS without requiring an , streamlining uncrewed logistics compared to capsule-based systems. The aft-attached Shooting Star module enhances capacity with 3,175 kg of unpressurized space, including internal storage and three external payload mounting points for experiments or equipment. This variant supports fully autonomous docked operations for up to 75 days at the ISS, enabling extended cargo utilization without crew intervention. Power during docking is provided by two deployable solar arrays on the module, generating necessary electricity for systems and payloads. The airframe of the Dream Chaser is reusable, designed for at least 15 missions following landings and refurbishment, which promotes cost efficiency over multiple flights. In contrast, module is single-use and jettisoned before re-entry to avoid thermal loads. The first operational vehicle, Tenacity, achieved full integration of the spaceplane and Shooting Star module in late 2023 and is slated for an uncrewed demonstration flight in late 2026 aboard a rocket. As of November 2025, Tenacity has completed key pre-flight testing milestones, including and compatibility tests.

Crewed Variant

The crewed variant of Dream Chaser, previously designated as the DC-200 series, is designed to transport up to seven astronauts to (LEO) for missions such as (ISS) resupply and crew rotation. This configuration builds on the lifting-body design originally conceived for , emphasizing reusability and landings to enhance operational flexibility. The vehicle incorporates an integrated using solid rocket motors mounted on the adapter between the spacecraft and the , enabling pad abort capabilities to separate the crew module from the booster in emergencies. The environmental control and (ECLSS) for the crewed variant maintains a sea-level within the cabin, with crew members wearing pressure suits during ascent, entry, descent, and landing phases to ensure safety. This system supports essential functions including air revitalization, temperature control, and , tailored for short-duration LEO missions. The cabin layout features a pressurized crew compartment with a dorsal hatch for ground access and crew ingress/egress at the launch site, while an aft hatch serves as the primary docking port compatible with the Docking System (NDS) for ISS interface. Interior accommodations include seating for up to seven astronauts, integrated displays for vehicle control and monitoring, and provisions for personal equipment storage, all arranged to facilitate operations during nominal and contingency scenarios. Development of the crewed variant advanced through NASA's Commercial Crew Development (CCDev) program, receiving Phase 1 funding in 2010, but was not selected for the Commercial Crew Transportation Capability (CCtCap) contracts awarded in 2014, leading to a pause in dedicated human-rated efforts and workforce reductions at (now ). Despite this, the design remains structurally compatible with the variant's airframe, allowing potential adaptation for future crewed operations on commercial space stations as prioritizes uncrewed demonstrations. Key safety features include full ascent abort coverage from to orbital insertion, enabling the vehicle to maneuver to a using onboard hybrid rocket motors without designated "black zones" of limited escape options. Additionally, the propulsive system provides a for de-orbit and contingency scenarios, leveraging the same elements shared with the configuration to ensure autonomous recovery.

National Security Variant

The National Security Variant of the Dream Chaser , previously designated as the DC-300 series by , is configured for U.S. Department of Defense (DoD) missions focused on responsive space operations and secure payload delivery. This variant supports the transportation of classified payloads to low-Earth orbit, enabling rapid deployment for objectives distinct from commercial resupply tasks. Although the specific DC-300 designation is no longer active, the configuration retains emphasis on defense applications, including potential missions for agencies like the (). Development interest from the DoD dates back to at least 2022, when began exploring Dream Chaser's use for point-to-point cargo delivery in collaboration with U.S. military entities, and continued into 2023 with visits from the U.S. Transportation Command to review the vehicle's capabilities. A significant advancement occurred in September 2025, when modified its Commercial Resupply Services contract to deprioritize missions, allowing a pivot toward national security priorities. This shift, announced alongside the establishment of the Defense division in June 2025, positions Dream Chaser as a versatile national asset for addressing pressing defense space challenges, with reusability rated for over 15 flights per vehicle. The variant leverages the base Dream Chaser's design for launch flexibility, compatible with multiple vehicles such as the , , and rockets to facilitate on-demand orbital insertions. Payload capacity for missions is supported up to approximately 5,500 kg to low-Earth orbit, with adaptations for secure handling of classified cargo. The vehicle's rapid reusability features a post-mission of about 60 days, enhancing operational tempo for time-sensitive defense requirements.

Applications

International Projects

In 2016, (now ) signed a (MoU) with the (ESA) and partners including to advance the Dream Chaser for European Utilization (DC4EU) program. This initiative entered a pilot phase to enable European access to the (ISS) or future orbital destinations using the Dream Chaser as a cargo vehicle, emphasizing its reusable lifting-body design for runway landings. A proposed variant tailored for ESA operations would leverage the rocket for launches, facilitating independent European missions beyond U.S.-dependent systems. Sierra Space has pursued collaborations with the United Nations Office for Outer Space Affairs (UNOOSA) to promote equitable access, beginning with a 2016 agreement for a dedicated Dream Chaser mission open to all UN Member States. This partnership evolved in 2019 with a call for interest in landing sites for a mission carrying microgravity experiments, which closed on April 30, 2020; as of November 2025, there are no active rounds. The initiative, particularly encouraging participation from developing countries to foster technology development and international cooperation, represents the first UN-sponsored multi-country mission, aiming to enable opportunities for nations with limited . Potential services extend to other global operators, including the Japan Aerospace Exploration Agency () and the Canadian Space Agency (CSA). Sierra Space established partnerships with in 2014 to explore mission concepts and Japanese technology integration for Dream Chaser applications. An MoU with CSA in 2017 further outlined possibilities for using the spacecraft in future Canadian missions, building on active interests from both agencies. As of 2025, these international engagements remain contingent on the success of Dream Chaser's free-flyer demonstration mission, now targeted for late 2026, amid ongoing development delays. International projects face challenges from U.S. export controls under the (ITAR), which restrict the sharing of sensitive technologies and limit deeper collaborations on proprietary systems. These regulations have historically complicated global partnerships by requiring extensive licensing for foreign involvement, potentially hindering technology transfers in joint missions. Despite this, the Dream Chaser Global Project seeks to expand non-U.S. utilization, positioning the vehicle for broader orbital logistics and equity in access through sustained diplomatic and technical engagements.

Planned Missions

The inaugural flight of the Dream Chaser , designated SSC Demo-1, will feature the Tenacity vehicle operating as a free-flyer launched aboard a rocket from no earlier than late 2026. This demonstration mission focuses on validating key technologies, including autonomous reentry, precision runway landing, and overall flight performance, without attempting to dock with the . Post-demonstration certification, anticipated by the end of 2026, the cargo variant could support up to seven Commercial Resupply Services-2 (CRS-2) missions to the ISS beginning in 2027, delivering pressurized and unpressurized cargo while returning items to Earth. These operations hinge on exercising options under the revised CRS-2 contract, which no longer mandates a fixed number of flights but preserves the potential for such resupply tasks through 2030. Beyond NASA missions, Dream Chaser is slated for commercial demonstrations to private destinations, such as —a and partnership aiming for operational status in the late 2020s—enabling cargo transfer and logistics support for low-Earth orbit habitats. The vehicle will also pursue missions for the Department of Defense post-demonstration, capitalizing on its rapid reusability and secure payload delivery for defense-related payloads. Primary launches for these missions will occur from , with potential utilization of for select operations depending on vehicle and payload configurations. The broader timeline carries risks tied to certification milestones into 2026; as of November 2025, Tenacity has completed electromagnetic interference/compatibility testing, tow testing, and command demonstrations, and post-landing recovery rehearsals at NASA's , with acoustic testing scheduled for December 2025. targets a production fleet exceeding 10 vehicles by 2030 to meet sustained demand across these applications.

Vehicles

Prototypes

The development of the Dream Chaser involved several non-flight prototypes and test articles to validate design elements, including cabin layout, , structural integrity, and . These ground-based and captive-carry assets were critical for reduction prior to building orbital-capable vehicles. A full-scale of the Dream Chaser crew cabin was constructed in at Sierra Nevada Corporation's (now ) headquarters in , primarily to assess cabin ergonomics, crew ingress and egress, and assembly processes. This enabled early evaluation of human factors, such as visibility from the cockpit and internal volume utilization, supporting NASA's Commercial Crew Development (CCDev) Phase 1 requirements. It facilitated training for technicians on vehicle assembly and integration techniques, ensuring manufacturability before advancing to more advanced hardware. In 2013, an testbed was established as a ground-based simulator to integrate and validate the spacecraft's software and electrical systems. This facility supported and testing throughout the Commercial Crew Integrated Capability (CCiCap) program, allowing engineers to simulate flight scenarios, debug avionics interactions, and verify system reliability without risking flight hardware. The testbed was instrumental in achieving CCiCap Milestone 6, the Integrated Systems Safety Review, by demonstrating safe operation of flight software in a controlled environment. The structural test article, completed in 2015, underwent rigorous ground testing to confirm the vehicle's ability to withstand launch and reentry loads. Conducted at the University of Colorado's Center for Infrastructure, Energy, and Space Testing (CIEST), the article was subjected to simulations, static load tests mimicking impacts, and axial loads replicating solid rocket motor during ascent. Over 200 strain gauges and displacement sensors provided real-time data, validating finite element models and ensuring structural margins met safety standards. These tests confirmed the composite airframe's durability under extreme conditions without failure. Aerodynamic validation occurred through the Engineering Test Article (ETA), a full-scale drop test vehicle used from 2013 to 2017 for approach and landing demonstrations. The ETA underwent captive-carry flights and free-flight drops from helicopters at NASA's , simulating unpowered reentry glides to verify stability, control systems, and autonomous landing precision. The 2013 test encountered a landing gear deployment issue, leading to a runway excursion but providing valuable data on gear mechanisms; the 2017 retry achieved a flawless touchdown at 191 mph after a 4,200-foot rollout, confirming aerodynamic performance. Subscale models supplemented these efforts with wind tunnel testing, though no aerial drops from high-altitude platforms like the B-52 were conducted for Dream Chaser. By 2020, most prototypes, including the , , structural test article, and , were retired following completion of their validation roles. Data from these assets directly informed the and of operational flight units, reducing development risks for subsequent and crewed variants.

Flight Units

The Dream Chaser flight units represent the operational phase of Sierra Space's reusable program, transitioning from prototypes to production vehicles designed for resupply missions under NASA's Commercial Resupply Services-2 (CRS-2) contract. The lead unit, Tenacity (designated SNC-001 or DC-101), is the first variant built for orbital flight. Its composite airframe, constructed at Sierra Space's manufacturing facility in , was completed in November 2023. Following vibration and environmental testing at NASA's A. Armstrong Test Facility, Tenacity arrived at in May 2024 for final systems integration, propulsion installation, and launch preparations. In November 2025, Tenacity completed electromagnetic and compatibility testing, with final acoustic testing planned for December 2025, followed by hot-fire and integrated hardware/software tests; integration continues at the Space Systems Processing Facility, with the vehicle on track for a demonstration flight no earlier than late 2026. Sierra Space is expanding production to support a fleet of Dream Chaser vehicles, with the second cargo unit, Reverence (DC-102), production paused as of November 2025 at the Louisville facility to prioritize Tenacity's maiden mission. This build draws on lessons from prototype ground tests to refine manufacturing processes for scalability. While specific timelines for additional units remain fluid amid evolving NASA contracts, Sierra Space aims to deliver multiple cargo vehicles to fulfill at least seven CRS-2 missions through 2030, potentially including two to three more units by 2028 to enable high-flight-rate operations. Each Dream Chaser flight unit features a reusable design certified for a minimum of 15 missions, emphasizing rapid turnaround through modular subsystems and automated diagnostics. Post-flight refurbishment is planned at facilities such as Kennedy Space Center's Operations and Checkout Building or Vandenberg Space Force Base, focusing on thermal protection system inspection, propulsion servicing, and airframe maintenance to minimize downtime between launches. As of November 2025, the inventory includes one unit (Tenacity) undergoing final testing and outfitting at and production of the second unit (Reverence) on hold, positioning the program for operational cadence once initial flights validate the design.

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  96. https://www.faa.gov/space/stakeholder_engagement/Sierra_at_SLF_VSFB
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