Pioneering Acoustic Testing Prepares the Shooting Star® Cargo Module for ISS Missions

For the inaugural acoustic testing at NASA’s Space Processing Facility at Kennedy Space Center, ARS had the honor of conducting the Direct Field Acoustic Noise (DFAN) test for Sierra Space’s Shooting Star® Cargo Module. This module, a multi-functional component developed by Sierra Space, is designed to expand the cargo capacity of the Dream Chaser® spaceplane. With the ability to transport over 7,000 pounds of supplies, scientific instruments, and food to the ISS, it plays a vital role in supporting various missions within the Low Earth Orbit economy. Equipped with solar arrays for additional power and thrusters for extra maneuvering, the Dream Chaser, including the Shooting Star®, is capable of executing even the most complex missions. After fulfilling its mission at the ISS, the Shooting Star® Cargo module is jettisoned and burns up in the atmosphere, marking it as an expendable but effective asset to commercial spaceflight.    

ARS offered Sierra Space cost-effective solutions, reducing the need to transport the spacecraft to external test sites. Our technology was instrumental in preparing the Shooting Star® for the severe conditions it will encounter during launch. The DFAN test by ARS comprehensively simulated the extreme acoustic and vibrational stresses expected during a launch on a Vulcan Centaur rocket. This test marked the first DFAN assessment of the Shooting Star® Cargo module and was also the first on-site DFAN test at NASA’s renowned Space Systems Processing Facility (SSPF). The ARS team employed our cutting-edge Neutron™ System, featuring a setup of 48 acoustic devices deployed in an 8×6 configuration. These devices were strategically arranged in 21-foot-tall columns around the spacecraft to generate a controlled sound field, allowing ARS to expose the Shooting Star module to sound waves 10,000 times more intense than those at a typical rock concert, surpassing 140 dB. Over four days, the module was subjected to several well-controlled high-intensity runs, ensuring its structural components could endure the noise and vibrations of an actual rocket launch.   

DFAN testing is pivotal for ensuring space vehicles can withstand the brutal conditions of space. ARS successfully replicated the acoustic forces of a rocket launch by surrounding the Shooting Star® Cargo module with our Neutron™ System, specifically designed for high-output aerospace acoustic assessments. The objective of DFAN testing is to simulate the intense sonic pressures experienced during a launch, which could greatly stress the spacecraft’s structure. The ARS team carefully crafted the test environment to replicate the conditions of a Vulcan Centaur rocket launch, ensuring every potential acoustic stress source was addressed. Consequently, the Shooting Star® module withstood acoustic energy exceeding 140 dB for several consecutive minutes, testing not only the durability of its structural components but also the functionality of its onboard systems. 

These tests mark a significant milestone in the development of this module as it prepares for its maiden flight to the ISS. ARS’s involvement in the DFAN testing of the Shooting Star® cargo module aimed to ensure the spacecraft’s readiness for upcoming missions, enabling the safe delivery of cargo to the ISS. Jeremiah Leiter, CEO of ARS, emphasized our organization’s commitment to providing advanced acoustic testing services. “Our goal is to accurately simulate launch conditions to ensure Sierra Space’s Shooting Star® cargo module is prepared for its first mission to the International Space Station.”   

Traditionally, acoustic testing was done in specialized facilities designed to mimic the harsh sound and vibration environments typical of rocket launches. These facilities often used large, permanently constructed reverberant chambers, which were both costly and highly specialized. However, by offering a mobile Neutron™ system configuration, ARS conducted an on-site DFAN test at the SSPF, representing a major paradigm shift. Simultaneously, ARS leveraged SSPF’s existing infrastructure to bring high-performance acoustic testing capabilities directly to Sierra Space’s location, highlighting the flexibility and technological advancement of the ARS Neutron™ system in acoustic testing while saving time and reducing risk.   

The collaboration between ARS and Sierra Space underscores the crucial role of rigorous testing in the commercial space industry, ensuring new technologies are flight-ready and capable of meeting the demands of today’s space missions. The ARS team is immensely proud to have participated in the first on-site DFAN test at the SSPF and the successful qualification of Sierra Space’s Shooting Star® cargo module. This represents a significant milestone in our partnership with Sierra Space, and we look forward to continuing our collaboration as they prepare for upcoming missions, including the major acoustic test for the Dream Chaser® spaceplane.

For more information, visit these news articles:

https://www.sierraspace.com/press-releases/sierra-space-shooting-star-cargo-module-completes-acoustic-testing-at-nasas-kennedy-space-center/
https://spacenews.com/sierra-space-completes-acoustics-tests-of-dream-chaser-cargo-module/
https://www.businesswire.com/news/home/20240904819264/en/Sierra-Space-Shooting-Star®%EF%B8%8F-Cargo-Module-Completes-Acoustic-Testing-at-NASAs-Kennedy-Space-Center