Experimental Spaceplane (XS-1)

Home , Spaceplane

10/2/2014

First Step Toward Reducing the Cost of Space Access by Orders of Magnitude

Mr. Jess Sponable Program Manager

Program Overview for COMSTAC

16 September 2014

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U.S. Launch – A Growing Problem

• DoD payloads launched on Evolved ELV at ~$3B/year & growing • Small payloads launched at ~$50M on few remaining Minotaurs • Foreign competitors lead commercial launch, once dominated by U.S. • No surge capability, long call-up times, typically > 2 years • Budgets continue to decline, threats to space and air assets growing

Falcon Evolved ELV ~5-15 flts/yr ~8 DOD flts/yr ~$54-128M/flt > $400M/flight Foreign Boosters Pegasus 70m ~60 Commercial & Gov’t flts/yr Minotaur > $120M/flight 60m Antares ~ 1 flt/yr 50m ~$55M/flt

40m

United States Foreign Distribution Statement A – Approved for Public Release, Distribution Unlimited 2

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Experimental Spaceplane (XS-1) Step One to Routine, Low Cost Access to Space XS-1 Vision • Break cycle of escalating space system costs • Aircraft-like operability enabling low cost, responsive access to space • Accelerate introduction of hypersonic technologies and next generation aircraft • Responsive platform for global reach national security and commercial applications • Enable residual capability for responsive launch of 3,000 – 5,000 lb payloads

Open Design Space Technology Technical objectives • Reusable first stage • Configuration Fly XS-1 10 times in 10 days • Fly XS-1 to Mach 10+ at least once Propellants • Launch demo payload to orbit • Design for recurring cost ≤ 1/10 Propulsion CONOPS Minotaur IV (< $5M/flight for 3,000 – 5,000 lbs to LEO at 10+ flts/yr) Up To Industry Artist Concepts

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Notional Government Reference X-Plane One of Many Possible Industry Solutions

F-15 XS-1 Mach 10 staging with small upper stage (shown) Alternative would be Mach 5 staging with larger upper stage

700 Payload = 3,025 lbm 61.6 ft 100x100 nmi 600 28.5 deg Inclination

Artist Concepts 2-Stage Vehicle (GLOW-223.9K lbs) Booster 500 Booster (2-Merlins) Propellant = 176.5K lbs Engine 2 Merlins ISP (vac) = 310 sec GLOW (K lbs) 223.9 400 PMF = 0.84 Upper Stage (GLOW-15K lbs) MECO (K lbs) 47.4 ISP (vac) = 336 sec Usable LOX/RP (K lbs) 176.5 300 PMF = 0.90 Isp (vac) 310 Altitude, K ft Altitude, Stage PMF 0.84 200 Upper Stage Staging: Time = 169.9 sec GLOW (lbs) 15.0 100 DR = 71.9 nmi Isp (vac) 336 Altitude = 237,155 ft Stage PMF 0.9 Mach = 10.8 0 Payload (K lbs) 3.0 0 100 200 300 400 500 600 Expendable stage ~5% of stack weight Downrange, nmi

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XS-1 Phase I Awards

• Phase 1 system awards The Boeing Company working with Blue Origin Northrop Grumman working with Virgin Galactic Masten Space Systems working with XCOR

Artist Concepts Artist Concepts

• Technology awards/cooperative efforts Honeywell – Real-time abort trajectory generation Gloyer-Taylor Labs – Composite cryogen tank fabrication and test NASA Armstrong Flight Test Center – Fiber Optic Sensor System (FOSS) SAS and LLNL – Ox Rich Staged Combustion / Next-Gen Rocket seedlings ATK/COI – CMC Thermal Protection Systems CCAT – Carbon Carbon Thermal Protection Systems • Upcoming awards • 2 Propulsion • 1 Comm / Space-Based Range Award Distribution Statement A – Approved for Public Release, Distribution Unlimited 5

XS-1 Planned Schedule

FY 14 FY 15 FY 16 FY 17 FY 18 FY 19

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

Source Selection PDR Phase 1- Initial KO Phase 1 Design Propulsion - Risk Reduction Airframe - System Design XS-1 Design Integration

Select CDR Phase 2 – Final XS-1 prime Phase 2 Design Fabrication XS-1 Design and IA&E Fab - Reusable aircraft IA&T - Upper stage Upper Stage Integration

1st Flight Orbital Phase 3 - Flight Test Flight Campaign Phase 3 Technology Transition Off-Ramps - Transition Opportunities USAF, NASA, Industry IDIQ

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Long Spaceplane History

AFSPC MNS 1-01 MNS 2-01 SUSTAIN SAC SON 7-79 AFSPC MNS 6-84 CONOPS Spacelift PGS ICD 80 82 84 86 88 90 92 94 96 98 00 02 03 04 05 WWII-era German Sanger Concept X-15 Rocket Plane Program (Plus other rocket planes) USAF Aerospace Plane Program, early 1960’s X-20 Dynasoar Program, 1960s Science Dawn, Science Realm, TAV, SSTO Studies MAV, Copper Canyon

$35M Have Region Artist Concepts $3,000M National Aero-Space Plane

$70M DOD DC-X Program

NASA Programs

Orbital Test Vehicle X-40/X-37

AFRL Ground Tech Maturation $200M +

Long USAF Push for Aircraft-Like Access to Space Distribution Statement A – Approved for Public Release, Distribution Unlimited 7

Legacy of Past Programs

Space Shuttle NASP NASPArtist Concept VentureStar $3 billion

Artist Concept Initial Goals NASA human rated AF crewed NASA human rated (requirements) Payload – 65K lbs Payload < 10K lbs Payload - 65K lbs SSTO, scramjet powered SSTO, rocket powered Aircraft-like ops, fast turn Aircraft-like ops, fast turn Technology TRL ~3 and immature design TRL ~2 and immature design TRL ~3 and immature design (at start) New LOX/LH 2 SSME New LS/RAM/SCRAM/rocket Mod LOX/LH 2 aerospike rocket Unproven materials/TPS New materials/structures New composite structures Toxic OMS/RCS, etc. New LOX/LH 2 tanks New metallic TPS 1960s/1970s technology New hot structure TPS, etc New LOX/H2 tanks, etc.

Approach Expendable launch (SRB, ET) X-Plane first X-Plane first Operational after 4 flights Incremental flight test Incremental flight test Evolved to “space station” Outcome Successful flights Never flew Never flew Very expensive with Design never closed Design never closed ground “standing army” Technology not available Technology not available

Past programs over-specified the problem (SSTO, scramjet, heavy lift, crewed, etc.) AND relied on immature designs and technology (TRL 2/3)

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What Has Changed? 20 years of investment Technology mature & affordable

Affordable Composite “Trimmed” Integrated Airframe Full Envelope Systems Health + Thermal AG&C Management Protection Systems

Low Cost Autonomous Responsive Upper Stage Operations Ops FOCC Design Integration Integrated Aircraft-Like Ops RLV Subsystems Affordable Infrastructure Artist Concepts Ongoing Long Term High Ops Tempo Propulsion

Off-the-Shelf propulsion available for demo

Cycle of Prep, Launch, Recovery, and 250k lbf. thrust Brassboard Demos Turnaround within Single Day

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XS-1 Goals

1. Break cycle of escalating space system costs Path to Affordable Space • GPS Blk III Seeking path to affordable space Sat $300-500M, Launch $300M Smaller satellites • Would enable disaggregation & Shorter lifetimes resiliency strategies Increasing One obsolescence Fly more often • 10X lower launch cost Example of Bigger satellites Today’s Cost Greater complexity More failure changes how spacecraft tolerance Growth Longer development are built Spiral Fewer satellites Less redundancy Longer life Greater redundancy More frequent tech refresh Blk I: Sat $43M, Launch $47M 2. Enable new types of aircraft & test capabilities • Space access aircraft Global ISR and protection Artist Concepts • Affordable hypersonic aircraft Low parts count & CTE structures/TPS Artist Concepts • Hypersonic testbed boost-glide systems & hypersonics Artist Concepts

Artist Concepts Artist Concept

Artist Concept Artist Concept Artist Concept Modular Bi-mese 3. Enable residual capability • ORS Launch single smallsat or constellations for rapid employment • Support growth options including near-term modular options Artist Concept Distribution Statement A – Approved for Public Release, Distribution Unlimited 10

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DARPA Leadership Perspective: Attack the cost equation Collectively the space portfolio is supporting responsiveness and cost reduction of launch through ground-based systems.

Airborne Launch Assist Space Access The E xperimental Spaceplane (XS-1) (ALASA) aims to enable responsive reusable vehicle capability would launch of 100 lb payloads from existing extend this capability to 3,000 lb globally distributed airfields to enable payloads with “aircraft-like” access to next-generation tactical missions space at 10X lower costs

Artist Concept Artist Concept All images are artist’s concept Distribution Statement A – Approved for Public Release, Distribution Unlimited 11

Challenges to Achieving Lower Cost XS-1 would complement heavy Falcon & EELV payloads

ELV Launch Cost Breakdown 100 Mission Conventional Assurance, Launch Vehicle $0.20 Facility, Trendline Small Solid support, Launchers launch complex, Launch $1.32 Vehicles, Delta II $1.44 EELV Variants Variants

10 Technical Challenges ALASA • Design and system integration enabling “aircraft-like” operations • (k$/lbm) Specific Cost Light weight/high energy airframe, Falcon 9 high propellant mass fraction XS-1 Trade Space • Durable thermal structures/ protection, -300 oF to +3,000 oF • Reusable, long life & affordable 1 propulsion 0.01 0.1 1 10 100 Payload to LEO (klbm) Note: Data extracted from FY12 PE/BPAC data, Excludes AFSPC payroll at launch sites and base O&M Distribution Statement A – Approved for Public Release, Distribution Unlimited 12

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Goal: Design and System Integration Enable “aircraft-like” operations Design for Rapid Turn Reduces Manpower Mission 600 Assurance, Delta II Baseline Data $0.20 Facility, 500 AUTONOMOUS VEHICLE, NO SOLID BOOSTERS, SIMPLE support, STAGE, etc. launch INCREMENTAL FLIGHT TEST complex, 400 PAYLOAD STANDARD INTERFACES $1.32 300 ON BOARD HEALTH MONITORING ON BOARD SELF TEST 200 AUTOMATED CHECKOUT OPS FLOW MGMT

Turnaround (hours) Turnaround 100 SPECIAL GSE

0 Few Facilities, Small Crew Size Launch Site/Base Manpower Comparisons Clean pad

Today’s Launch Complex

Complex to Simplex

Autonomous Ops ISHM Goal Manpower/Aircraft

Incorporate “-ilities” Distribution Statement A – Approved for Public Release, Distribution Unlimited 13

Goal: Design Integration “Clean Pad” Aircraft-Like Operations

• Aircraft-like CONOPS CLEAN PAD CONOPS – Clean pad - rapid throughput Rapid Throughput, < 24 hrs on pad – Ops Control Center – like aircraft Artist Concepts – Containerized payloads • Aircraft GSE/Facilities where practical – Hangars, not specialized buildings – Standard interfaces/processes – Automated ops, propellant & fluid loading

OPS CONTROL CENTER • Small 3 Person Ops Crew Size Integrated Systems Health Management – Determine real-time system health – Integrate with Adaptive G&C – Enable reliable, rapid turnaround aircraft • Leverage high ops tempo investments – ALASA – Autonomous Flight Termination System – ALASA – Rangeless range, space based command, control & data acquisition – Flight Manager Deputy FM Crew Chief Adaptive GN&C – safe, reliable recovery/abort (FM)

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Goal: Light Weight / High Energy Airframe High Propellant Mass Fraction (PMF)

Mission Tank/Structure Integration Assurance, Integral load bearing structure $0.20

Launch Vehicles, $1.44 High PMF key to performance 1 V = I g ln SP * * 1 - PMF Affordable Structure Composite Structures Reduce 10X fewer parts & lower cost Weight ~30% aka NASA X-55 Open-Core Tank in Fabrication Reusable vehicle cost would be amortized rapidly … USAF Monocoque Tank in Unit Cost Test No. Flights

Design tank / airframe structure to enable high PMF/∆V

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Goal: Durable Thermal Structures / Protection -300 oF to +3,000 oF How you design & fly is key! 100 POST Results Ref Reentry AOA – 30 o 13.3K Heating on 1 ft Reentry AOA – 70 o 80 BTU’s/ft 2 Radii Leading Mach 10 suborbital Edge2

/sec) <2K BTU’s/ft 2 2 60 51K BTU’s/ft Launch

Vehicles, Rate Heat 40

$1.44 (BTU/ft 20

Time (sec) 500 1,000 1,500 Many Thermal Protection Options Emerging Thermal Structures AFRSI and CRI Quick- Release Fastener

Leading Edges ACC, C/SiC, TUFROC Composite Hot Structures

Fibrous Opacified Insulation

Space Shuttle Post- Aircraft Flight CMC/TUFI Mechanical Atch Honeycomb Composites Hot Wash Tiles Structures Distribution Statement A – Approved for Public Release, Distribution Unlimited 16

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Goal: Reusable, Long Life and Affordable Propulsion Multiple Options – Design Integration Challenge

Mission Use existing propulsion with mods for Assurance, • Long life … rapid call up/turnaround … $0.20 deep throttle • High reliability … historically, most launch failures caused by propulsion Launch Vehicles, Design as Line Replaceable Unit $1.44 • Rapid remove and replace • Support high ops tempo flight rate

Multiple Affordable Propulsion Options

STA

M R XCOR O O D C U K L © XCOR Aerospace E © Space Exploration A T Technologies R Merlin NK-33 SSME Commercial Stockpiled Space Rocket Russian Shuttle Engines Ventions Rocket Distribution Statement A – Approved for Public Release, Distribution Unlimited 17

OV-1 Derived Capabilities

Enabled Futures Global Reach Capability Step One: S-1 100X lower cost 3-5K Payload

10X lower cost Fully Reusable Vehicle

Expendable 2nd Stage

Fighter Sized Demonstrator

Hi Speed Aircraft Flexible Launch & Landing Options Fly from Anywhere, Anytime

Delivers affordable, routine space access - On path to global reach capability

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XS-1 Capabilities Would Evolve Over Time

Deploy mated satellite & stage • Core capability > 3,000 lbs to LEO Option: Grow capability with modular launch

Modular Bi-mese • Payload disaggregation could shrink sizes Downsize & modernize payloads Disaggregated Satellite Missions Single payload siimplified spacecraft

• Stage disaggregation would grow effective Autonomous Dock of Chemical Stage/Sat payload Launch satellite payloads separately Solar Electric Dock stage on-orbit with satellite Propulsion Artist Concepts • Grow launch markets • Capture / recapture commercial launch 10 Boost Glide • Enable new military / ORS capabilities 5 • Hypersonic testing / release of free-flyers Free Flyer Hypersonic Test Burn Out Mach No. Mach Out Burn

Downrange Constant Q Flight Profile Distribution Statement A – Approved for Public Release, Distribution Unlimited 19

Potential XS-1 DOD and Commercial Satellite Markets Responsive launch of 3 to 5K lb payloads XS-1 Capture of Historical • 70 U.S. Launches: 1993 to 2012 ‘97-’99 spike due to Iridium and Globalstar • 60 Lost commercial opportunities Satellite/Stage Mass • 50 Commercial launch migrated overseas 10,000–15,000 lbs … $Billions in lost revenue 40 5,000–10,000 lbs … Grew cost of DOD launch 30 < 5,000 lbs (XS-1) • New constellations hard to finance 20 … Teledesic 10 0 © Teledesic No. Satellite Launches Captured Captured SatelliteLaunchesNo. 1993 1995 1997 1999 2001 2003 2005 2007 2009 2011 Note: All satellites launched on U.S. boosters. U.S. satellites launched on foreign boosters. Excludes classified & crewed flights. Counts satellites >1K lbs, aggregates smaller satellites. • Potential to leverage commercial sector Worldwide Projected Payloads: 2013 to 2022

800 © Stratolaunch © Virgin Galactic > 70 Launches/yr Systems © Blue Origin 600 © Space Exploration 400 Technologies © XCOR Aerospace • Missions potentially enabled by XS-1

No. Payloads No. 200 0 • USAF ORS & “disaggregated” satellites • Recapture commercial launch Historical avg of 3-5 launches/yr at 5,000 lbs

Note: Data from Teal Group, Projected market much higher Aerospace America, June 2013 Mass (lbs) Distribution Statement A – Approved for Public Release, Distribution Unlimited 20

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XS-1 Could Facilitate Next Gen Hypersonics

Multiple Test Options Constant Q Unpowered Glide • Captive carry experiments from Engine Burn Out • May Limit Q and thermal testing 15 • Propulsion (RAM/SCRAM/Turbine) • Airframe/Structures Free • Thermal Protection Flyers • Release free-flyer experiments 10 • Unpowered constant Q reentry Captive • Long test time vs. ground test Carry • Aerodynamic & thermal test 5 • Laminar flow/boundary layer transition

• Controls/avionics No. OutMach Burn Constant Q Test Time • Powered test vehicle ~90 sec ~120 sec ~300 sec • Longer flight tests Artist Concepts • Useful test data limited only by scale 200 400 600 800 and cost Downrange (nm)

Projected Cost of Flight Test < Many (Not All) Ground Tests Test of component/systems ♦♦♦ RAM/SCRAM/turbine ♦♦♦ Boost-glide vehicles Distribution Statement A – Approved for Public Release, Distribution Unlimited 21

XS-1 Transition Path Would Require Proactive Industry

Robust DOD and commercial launch industry with ideas

© Stratolaunch Systems © Sierra Nevada Corporation © XCOR © Space © Virgin Aerospace Galactic Exploration © Space Exploration Technologies © Blue Origin Technologies Growing small satellite industry building low cost satellites • Commercial • Military • Civil

© Globalstar © Skybox © Orbital Imaging © Teledesic Sciences Emerging DOD requirements for disaggregation & resiliency • Disaggregation: downsize spacecraft for routine, responsive & affordable launch • Resiliency: ability to operate in the harsh space environment

Industry Would Lead Commercial and Military Transition Options

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Stepping Stone to Future Capabilities Technology scalable to future capability Proposed XS-1 Program

Space Access/ISR Vehicle Bare Base Mach 1-10 CONOPS

Aircraft-Like operability Commercial National security global reach Capability architectures Artist Concept Demonstrate Commercial Launch for Enable AFSPC Full Spectrum Payload to LEO ORS, AF & Intel Launch Capability

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Flight Test Mach 10 Would Validate Critical Access to Space Technology

XS-1 Mach No. Mach

XS-1 will mature technology for 1 st Stage AND fully reusable flight to space

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XS-1 Seeks to …

• Push Mach capability well beyond suborbital tourism • Engage FAA-DOD-Industry teams to establish safe standards of practice for new launch systems • Leverage commercial sector technology (Blue Origin, Virgin Galactic, XCOR, etc.) • Transition vendor/subcontractor technology to commercial sector • Transition some system prime technology to commercial sector • Transition launch capability to commercial sector • Explore new missions like hypersonic testing and point-to-point transport • Enable more affordable launch expanding satellite opportunities • Serve as a step to fully reusable access to space technologies

Trailblaze next generation commercial space … … technology, flight envelope, regulatory, new markets, etc.

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Summary

Highlights • New era – Launch costs growing, budgets declining and threats proliferating • Disruptive – Order of magnitude lower cost new game changing capabilities • Leverage – Emerging suborbital and launch technology & entrepreneurs • Transition – Industry leads, many paths forward Commercial, DoD, civil XS-1 program could be an agent for change … … DARPA open to innovative industry proposals

Artist Concepts Artist Concepts Artist Concepts Artist Concepts Artist Concepts

Several Notional Concepts

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www.darpa.mil

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