Secondary Payload Adapters and Interfaces Technical Committee Report

17th Annual Small Payload Rideshare Symposium Johns Hopkins University/Applied Physics Lab

June 10, 2015

This committee reviews existing and conceptual secondary adapters, the vehicles on which they can be flown, their capabilities and limitations, as well as potential flight opportunities. Secondary adapters’ shortfalls in weight or volume, limitations in vehicle compatibility, and other issues and perceived needs are to be identified and documented. Manifesting and scheduling issues will be evaluated and documented along with suggestions for resolution or improvements. Secondary Adapters Technical Committee • US Government policy • US Rideshare Options • Smallsat‐to‐Launch Vehicle Interfaces • Adapters and Dispensers – CubeSat dispensers and adapters – Small Sat adapters – Propulsive adapters

Future Topics • Rideshare “Wiki Page” on SPRSA.ORG website • Hosted Payload Options • International Boosters/Rideshare Interfaces

NOTE: Some of the documented hardware does not yet have flight heritage. The information provided here is a guide; please consult with the vendor.

Rideshare 2015 2 Acronyms ABC Aft Bulkhead Carrier ALS Adaptive Launch Solutions APL auxiliary payload CBE current best estimate CG center of gravity CSD Canisterized Satellite Dispenser CYGNSS Cyclone Global Navigation Satellite System EM‐1Exploration Mission 1 EAGLE ESPA Augmented Geostationary Laboratory Experiment EELV Evolved Expendable Launch Vehicle ESPA EELV Secondary Payload Adapter FASSN Fast‐Acting Shockless Separation Nut HDRM Hold Down Release Mechanism ISIS Innovative Solutions In Space JHU/APL Johns Hopkins University/Applied Physics Laboratory LCROSS Lunar Crater Observation and Sensing Satellite LTDN local time of descending node MEV maximum expected value MLB Motorized Lightband NLAS Nanosatellite Launch Adapter System NPSCuL Naval Postgraduate School CubeSat Launcher NTE not to exceed OMV Orbital Maneuvering Vehicle Φ diameter of circle P‐POD Poly Picosat Orbital Deployer PSC Planetary Systems Corporation RSA Rideshare Adapter SNC Sierra Nevada Corporation ULA United Launch Alliance 3 National Defense Authorization Act, 2014

“The DoD Executive Agent for Space shall conduct a study on responsive, low‐cost launch efforts. Such study shall include … an assessment of the viability of greater utilization of innovative methods, including the use of secondary payload adapters on existing launch vehicles. … Not later than one year after the date of the enactment of this Act, the DoD Executive Agent for Space shall submit to the congressional defense committees a report containing (1) the results of the study … and (2) a consolidated plan for development within the DoD of an operationally responsive, low‐cost launch capability.”

• Report completed and in final Air Force coordination ‐ Signature expected June 2015 • Report to be delivered to Armed Services Committee ‐ Should be available for public release

Rideshare 2015 4 US Rideshare Options 2015 • Rideshare opportunities by third‐party brokers/integrators – Adaptive Launch Solutions (ALS) – NanoRacks LLC – Spaceflight Industries – TriSept Corporation – Tyvak Nanosatellite Systems Inc. • Large US vehicles w/ secondary capabilities – Antares (including Cygnus) [Orbital] – Atlas V [United Launch Alliance (ULA)/Lockheed Martin Commercial Launch Services] – Delta IV [ULA/Boeing Launch Services] – Falcon 9 (including Dragon) [SpaceX] – Falcon Heavy [SpaceX] – Space Launch System [NASA] • 11x 6U CubeSats will fly on EM‐1 2018

Rideshare 2015 5 US Rideshare Options 2015 • US small launchers – ALASA [DARPA/Boeing] – Alpha [Firefly] – Athena II [Lockheed Martin] – Electron [RocketLab] – Nano‐sat/Micro‐sat Launch Vehicle (NMLV) [Garvey Spacecraft] – GO Launcher 1, 2 [Generation Orbit] – LauncherOne [Virgin Galactic] – Minotaur I, IV, V, VI, C [Orbital ATK] – Neptune [Interorbital] – Pegasus [Orbital ATK] – Stratolaunch [Vulcan Aerospace] – SuperStrypi [Sandia National Labs] – Terrestrial Return Vehicle (retrieval from ISS only) [Intuitive Machines] – Ventions Nanolauncher [Ventions]

Rideshare 2015 6 US Rideshare Options 2015 • US space planes – DreamChaser [Sierra Nevada Corporation (SNC)] – Lynx [XCOR] – Rocketplane [Kistler] – Spaceship Two [Virgin Galactic] – XS‐1 [DARPA/Multiple Teams]

Rideshare 2015 7 Some Current Standard Interfaces • Φ62.01” (1575 mm), 120 x ¼” fasteners – Atlas V, Delta IV, Falcon 9, Antares, Minotaur IV, V, VI • Φ38.81” (986 mm), 60 x ¼” or #10 fasteners – Minotaur I, Athena, Taurus, Pegasus • Φ24” (610 mm), 36 x ¼” or 5/16” fasteners – ESPA Grande, CubeStack • Φ15” (381 mm), 24 x ¼” fasteners – ESPA, Atlas V Aft Bulkhead Carrier, Athena Rideshare Adapter • Φ8” (203 mm), 12 x ¼” fasteners – Small Launch ESPA, Athena Rideshare Adapter • Discrete point mounts – Configurations optimized per application • Many adapters can be flexible with customer interfaces – ALS Aquila/A‐Deck – CubeStack, ESPA, Moog CSA Plate Adapters – Design Net Rideshare Adapters (RSAs) – SNC Nanosatellite Dispenser/Adapter • S/C mounted w/ resettable HDRM‐4K sep nuts, kinematic mount Rideshare 2015 8 ESPA Interface, Separation Rings • Planetary Systems Corp Lightbands – MkII MLB24.000‐36: Φ24” 36 x ¼” fasteners – MkII MLB15.000‐24: Φ15” 24 x ¼” fasteners – MkIII Lightband in development • Increased performance, lower cost and delivery schedule • Available for spaceflight in 2016 • RUAG Clampbands – PAS 610S: Φ24” – PSR 1575: Φ62” • Sierra Nevada Clampbands – Qwksep 24: Φ24” 36 x 5/16” fasteners • Tapped or 0.332” clearance holes (holes for ¼” fasteners available) • 2015 update –development complete; qualification model built and ready for testing – Qwksep 15: Φ15” 24 x ¼” or 5/16” fasteners • Baseline 0.266” clearance holes • 2015 update – competitively awarded EELV auxiliary payload qualification contract by ULA

Rideshare 2015 9 Lightband Interfaces

• Φ38.810” 60 x ¼” fasteners • Φ31.600” 48 x ¼” • Φ24.000” 36 x ¼” • Φ23.250” 32 x ¼” • Φ19.848” 28 x ¼” • Φ18.250” 28 x ¼” • Φ15.000” 24 x ¼” • Φ13.000” 20 x ¼” • Φ11.732” 18 x ¼” • Φ8.000” 12 x ¼”

Rideshare 2015 10 Discrete‐Point Mounts

• SNC separation joints – HDRM 4k, 7k, 10k (formerly QWKnut) – FASSN 30K, 1500 • TiNi Aerospace separation joints – ERM E250, E500, E1000, E2000, E4000 • Ejector Release Mechanism part numbers represent max load in lbf • ORBCOMM Generation 2 satellites on ESPA (with adapter plates), each utilizes four E4000 units • Applied Physics Lab (JHU/APL) Express platform: Satellites between 6U and ESPA‐class, especially 20‐50 kg – Satellite deployment uses separation interface with two sep nuts at opposite corners of 4‐point mount

Rideshare 2015 11 ESPA Four‐Point Mount ESPA Augmented Geostationary Laboratory Experiment (EAGLE) interface developed for propulsive ESPA ring – First copy of EAGLE ESPA replaces several of six ESPA ports with sets of four mounting pads for attaching hosted payloads – 4‐point‐mount interface also for use with separable satellites, up to 180 kg with 20‐inch CG offset, as in standard ESPA

Rideshare 2015 12 CubeSat Dispensers • Cal Poly P‐POD (Poly Picosat Orbital Deployer) 3U dispenser • Nanoracks ISS deployers: 3U, 4U, 6U • Planetary Systems CSD: 3U, 6U, 12U, 27U dispensers • TriSept/Moog FANTM‐RiDE generic smallsat dispenser family • Tyvak dispensers – Rail‐POD 1U, 3U, 6U dispensers – NASA Ames NLAS (NanoSat Launch Adapter System) 6U dispenser

• International products – ISIpod dispenser, ISIS [Netherlands] Marketed by Spaceflight in US as EZpod – JAXA ISS ejector, J‐SSOD [Japan] – NovaPOD and FlyMate, NovaNano [France] – SFL XPOD dispensers, U of Toronto [Canada]

Rideshare 2015 13 Tyvak Dispensers

• Tyvak 3U RailPOD – Ultralight 3U deployer

• Tyvak 6U NLAS Mk. II – Based on NASA Ames NLAS dispenser (heritage on ORS‐3, to fly on ORS‐4) – Various improvements and upgrades

• Tyvak 12U Modular Design – Using 6U as base module, larger form factors can be accommodated

Rideshare 2015 14 FANTM‐RiDE • TriSept/Moog collaboration 1/3rd Scale FR Dispenser • Mass‐tunable, containerized, stand‐alone dispenser system with mission integration services • Lined up first commercial Availability for APLs: 24” x 24” x 32”, 240lbs

customer for order of CubeSat Attach/Deploy Mechanism Prototype between 3 and 6 dispensers – Funding for final design, qualification testing, and flight unit delivery – Designated for June 2017 TriSept Dedicated Rideshare Mission (dRS‐1) • Continuing design towards PDR/CDR – Critical component designs near completion and/or identified COTS • Door hinges and latches, attachment/ deployment mechanisms, sequencer, etc.

Rideshare 2015 15 FANTM Variants • FANTM‐LiTE – Half version of standard FR dispenser – Designed to the Atlas V ABC interface – Same features of standard FR, but smaller FANTM-RiDE • FANTM‐Grande FANTM-LiTE – Larger version of standard FR dispenser – Design to containerize ESPA and above‐class SVs – Nominally interfaces with 24‐in ESPA Grande port • FANTM‐RAiL – Smallsat attachment/deployment rail kits FANTM-Grande designed to flexibly integrate smallsats without mass of a dispenser FANTM-RAiLs w/ 12U and 6U – Designed to adhere to PSC CSD standard combos – Can be spaced to integrate 3U, 6U, 12U, and above smallsats

Rideshare 2015 16 CubeSat Adapters • Aquila CubeSat accommodations by Adaptive Launch Solutions (ALS) • Naval Postgraduate School CubeSat Launcher (NPSCuL): 8x 3Us or 4x 6Us (or combinations) with Φ15” interface – Third mission on Atlas V Aft Bulkhead Carrier (ABC) May 2015 AFSPC‐5 deployed 10 CubeSats including Planetary Society LightSail • SpaceX Surfboard – Mounting tray installed on aft‐end of 2nd stage carries several 3U or 6U dispensers • Wafer adapters: Steve Buckley design for 8x 3Us or 4x 6Us (or combinations) with Φ38.81” interface, can also carry “primary” small sat – NLAS adapter by NASA Ames to launch on ORS‐4 late 2015 – CubeStack by LoadPath and Moog CSA

Rideshare 2015 17 CubeSat Adapters continued • Design Net Falcon 1e Rideshare Adapter: Multiple CubeSats with Φ38.81” interface, can also carry “primary” small sat • LM Athena Composite P‐POD Carrier (ACPC): Multiple CubeSats built into the Athena rideshare adapter • Moog ESPA SUM (6U Mount): 2x 3Us or 1x 6U dispenser with Φ15” interface; options for inboard and outboard on ESPA • PSC Canisterized Satellite Dispenser (CSD) has bolt patterns for mounting directly to launch vehicle or satellite interfaces – Dispenser structure permits attachment without dedicated adapter

Rideshare 2015 18 NPSCuL Status • Flight History/Manifest – 3 successful Atlas V missions, 33 CubeSats deployed: 2012 (OUTSat/NROL‐36), 2013 (GEMSat/NROL‐39), May 2015 (ULTRASat/AFSPC‐5) – Upcoming Atlas V mission September 2015, 13 CubeSats: (GRACE/NROL‐55) • SADv528 – Maximizes ABC capability to accommodate 8 P‐PODs with 5 LV‐provided deployment signals – Flown on ULTRASat/AFSPC‐5 as first‐flight item • NPSCuL COTS Isolators – Commercial‐off‐the‐shelf (COTS) isolators used with force‐limited vibration testing (FLVT) reduces P‐POD GRMS environment on NPSCuL up to 85% – “First‐class” ride to space for CubeSats and small spacecraft – Compatible with ESPA and Lightband LV interfaces and applicable to other ESPA‐ class spacecraft of similar size

Rideshare 2015 19 CubeStack Status • Enhanced design by LoadPath – New bulkhead structure provides greatly improved integration CONOPS – Overall weight reduction of 5‐10% depending on dispenser attachments – Identical primary P/L interfaces – Integrated harness allows payload monitoring/charging • Delta qualification test mid‐June 2015 – LoadPath/Moog CSA

Rideshare 2015 20 Design Net Falcon RideShare Adapter

• Developed with InStar Engineering • ORS‐1 launch on Falcon 1e June 2011

Rideshare 2015 21 Small Sat Adapters • ALS Aquila for EELV • CSA CASPAR Dual Payload Adapter for Minotaur IV – 74” adapter separation system not yet qualified • Design Net Rideshare Adapters • European Space Agency Vega Secondary Payload Adapter (VESPA) • LM Athena Rideshare Adapter • Moog CSA ESPA • Moog CSA plate adapter – 2011 GRAIL mission • SNC Nanosatellite Dispenser/Adapter • SpaceX ring adapters – 30+ payloads on Falcon Heavy mission

• Launch vehicle companies (and others) develop custom adapters based on need – Orbital STP S‐26 adapter for multi‐payload STP mission – SpaceX external payloads for ISS, e.g., International Docking Adapter (IDA‐1) Rideshare 2015 22 ALS Aquila Multi‐Manifest System Integrated stack compatible with EELV and SLV standard interfaces at aft end and with multiple spacecraft adapters at forward end • Adapters and A‐DECK with mass simulator

• A‐DECK being lowered into adapters

• Mass simulator sitting on A‐DECK

• Moving test hardware assembly into chamber

Rideshare 2015 23 SNC CYGNSS Adapter

System: Mass: 243.0 kg (CBE), 270.1 kg (MEV), 307.0 kg (NTE) Diameter, Envelope: 110.2 cm Height, Envelope: 122.4 cm Dispenser: Mass: 44.5 kg (CBE), 50.0 kg (MEV), 75.0 kg (NTE) Microsat (8x): Mass: 24.8 kg (CBE), 27.5 kg (MEV), 29.0 kg (NTE) CG Offset: 0.9 mm (axial), 1.4 mm (circumferential), 335.7 mm (radial) Launch Vehicle: Pegasus XL Interface, Mechanical: 24x 1/4‐20 nut plates on 35.56 cm (14") diameter bolt circle Loads: Pegasus User's Guide, Release 7.0 (April 2010) CYGNSS integrated payload stack

Rideshare 2015 24 Design Net EELV Rideshare Adapter

• Designed for Minotaur IV, Falcon 9, Atlas V – Developed under contract to NASA Ames Research Center – Qualification tested for Minotaur IV • Standard interfaces – Standard C‐Adapters – 15‐inch Lightband – 38‐inch Lightband • Stand‐alone Multiple Interface Payload Subsystem (MIPS) – Deployment, telemetry, power switching • Payload capability – Three NanoSat Class S/C – Extensions for 3U, 6U and 12U deployers • Weight 230 lbs

Rideshare 2015 25 Moog ESPA Family

• ESPA 6‐15‐24 (2000) for EELV 62‐inch interface – ESPA 15‐inch port is standard interface for small sats to 400 lbs • ESPA Grande (2004) – 24‐inch port size accommodates 700‐lb small sats – ESPA 5‐24‐42 selected by Spaceflight for SHERPA in 2012 Partial family portrait • Small Launch ESPA (2007) for 38.8‐inch LV interface – Rings with smaller LV interfaces (31.5‐ and 36.9‐inch) designed for international vehicles – Secondary interfaces up to 15 inches • Large diameter rings (2009) for LV diameters to 120 inches – International LV rings at 70 and 86.2 inches • EAGLE ESPA (2012) integral 4‐point small‐sat mount • Reduced weight rings for mission‐specific payloads – 2012 OMEGA mission for science constellation deployment

Rideshare 2015 26 Spaceflight SHERPA

SHERPA is an in‐space transportation platform by Spaceflight Industries that supports orbit raising and maneuvering of secondary spacecraft

SHERPA 1st Flight –Q4 2015: • LEO SSO 10:30 LTDN • Up to 1265 kilograms of Secondary Payloads • No Propulsion or Attitude Control

SHERPA Accommodations: • 5 ports, each supporting up to 300kgs • Dimensions NTE 1m x 1m x 1.2m • Hosted Option for Power/Comm up to 3 years

Future Capabilities: • 400 m/s Delta V for Altitude Maneuvers • 1000 m/s Delta V from GTO for delivery to Lunar Orbit • 2200 m/s Delta V from GTO to circularize up to 500kg payload in GSO

Rideshare 2015 27 SHERPA Adapters by Spaceflight

Radial Port Adapter Supports 15” and 11.732” Separation Systems

Dual Port Adapter (2 <80kg Satellites) Supports 11.732” and 8” Separation Systems

QuadPack Plate Hardware has arrived in Seattle Supports CubeSat Dispensers Upgrades to integration facility in process Currently Configured for ISIS QuadPacks

Rideshare 2015 28 Propulsive ESPA Programs • LCROSS 2009 by Northrop Grumman for NASA Ames – “Shepherding satellite” and lunar impactor • AFRL small business programs 2007‐2010 – Millennium Space Systems OMS • Ready for flight program – Busek Multi‐payload Utility Lite Electric (MULE) • Continuing development with ULA • AFRL EAGLE – Orbital ATK satellite bus and propulsion module – Moog Broad Reach avionics, software, GPS receiver • Spaceflight SHERPA – Multiple implementations • Unnamed program • OMEGA (Orbiting Medium Explorer for Gravity Astrophysics) – Moog/Surrey US team reviewed by JPL TeamX in 2012 • Moog OMV – Configurations in development

Rideshare 2015 29 Secondary Adapters Tech Committee members and contributors

• Michelle Voelker, SMC • Anthony Kyriakidis, ALS • Eric Anderson, SVSC • Mike Bender, Aerojet • Ryan Williams, PSC • Roland Coelho, Tyvak • Bryan Helgesen, SNC • Adam Hadaller, Spaceflight • Wenschel Lan, NPS • Christian Melbostad, SpaceX • Phil Brzytwa, Spaceflight • Ron Goedendorp, NanoRacks • Dan Lim, TriSept • Keith Karuntzos, ULA • Ken Brunetto, LoadPath • Warren Frick, Orbital ATK • Greg Sanford, LoadPath • Tom Johnson, GSFC • Justin Smith, Design Net • Gerry Murphy, Design Net • Jack Rubidoux, ALS • Aaron Rogers, JHU/APL • Ryan Nugent, Cal Poly • Clint Apland, JHU/APL • Justin Carnahan, Tyvak • Chris Loghry, Moog • Joe Maly, Moog • Eric Austin, Moog

Rideshare 2015 30