We talk about Dream Chaser fairly often around here and it was the subject of some comments recently. So how do we resist a story with a headline like, "Is the Dream Chaser space plane ever going to launch into orbit?" Especially when it's by one of the most experienced space writers out there, Eric Berger at Ars Technica. We don't resist. We dive in.
The first, question, and the obvious one is, "when is Dream Chaser going to fly?" Unfortunately, there's not a clear, easy answer to that. Except that considering we're pretty much 2/3 of the way through 2025, it's looking like it won't be this year. It's not quite as little as 1/3 of the year left more like 40%, but we're closing in on it.
Something I wasn't aware of is that Dream Chaser has been in development for over 20 years; I thought it was more like 10. I think we all see that it's a popular and well-regarded vehicle among the public although that's probably because it's winged shape is reminiscent of the Space Shuttles - especially with Dream Chaser covered in white and black heat-resistant tiles that resemble the shuttles' tiles.
Dana Weigel, program manager for the International Space Station, was asked about Dream Chaser at a news briefing on Friday, following the successful launch of the Crew-11 mission.
"They're in final assembly," she said of Sierra Space. "They're doing a lot of tests, and they're doing what I call final certification work. Some of the big key areas that they're focused on is the software certification. You've got to test end-to-end all the different software functions. So that's a big focus area for them. And then they're still working on certification in the prop system."
Prop system? She means the propulsion system - like the system on Starliner which managed to pretty much destroy the first crewed mission a year ago (launched in June).
There were some notable tidbits of news in this comment. First of all, it appears that NASA has learned its lesson from the first troubled flight of Boeing's Starliner spacecraft, which had significant software problems during its debut flight in December 2019. After this experience, it appears the space agency is requiring an end-to-end test of a spacecraft's flight software prior to visiting the space station.
Additionally, there is the fact that Sierra is still working to certify Dream Chaser's propulsion system.
The propulsion system is not something I've read much about before. Dream Chaser is powered by over two dozen small rocket engines, each capable of operating at three discrete levels of thrust for fine control or more significant orbit adjustments. "Over 24 engines with three thrust levels each" seems novel, but not as novel as the fact that the engines run on a mix of kerosene and hydrogen peroxide propellants rather than the more common, toxic, hypergolic propellants that ignite (pretty much "explode") on contact with one another.
"We wanted to have a fuel system that was green instead of using hypergolics, so we could land it on a runway and we could walk up to the vehicle without being in hazmat suits," Tom Vice, then Sierra's chief executive, told Ars in late 2023. "That was hard, I have to say."
Apparently it still is because, according to Weigel, the process to finish testing of the propulsion system and certify it for an uncrewed spaceflight remains ongoing.
Berger reports that according to one of his sources, Sierra Space is considering a change to the first mission that could conceivably shorten the certification period. They wouldn't dock with the ISS, instead just doing a flyby.
The company had planned to fly the vehicle close enough to the space station such that it could be captured and berthed to the orbiting laboratory. One option now under consideration is a mission that would bring Dream Chaser close enough to the station to test key elements of the vehicle in flight but not have it berth.
This would increase confidence in the spacecraft's propulsion system and provide the data NASA and partner space agencies need to clear the vehicle to approach and berth with the station on its second flight. However, this would require a modification of the company's contract with NASA, and a final decision has not yet been reached on whether to perform a flyby mission before an actual berthing.
Sierra Space's Dream Chaser space plane inside a NASA test chamber in Ohio.
Credit: Sierra Space
It seems like I said at the top, given that we're starting into the 8th month of the year, leaving a bit over a third of the year for this to be completed and a launch to happen, it seems like a safe bet that it's not going to happen this year. Another challenge is that it can currently only fly on ULA's Vulcan. The first Vulcan national security launch is listed on NextSpaceflight as this coming Sunday at 8:07 PM (from our neighbors' place 30-ish miles up the coast). Assuming this launch is successful, Vulcan has a busy manifest in the coming months for the US Space Force and we don't have much of an idea how flexible ULA can and will be in getting Dream Chaser flying.
At one point, Sierra had said they wanted Dream Chaser to be agnostic about what rocket gets it into orbit, hinting that it could fly on a Falcon Heavy. Ars Technica's article makes no mention of that.