Sierra Space to Blow Up its Biggest Space Station Yet

The over-pressurization to failure will demonstrate the habitat’s capabilities.

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Sierra Space

Sierra Space, a commercial space company building an end-to-end business and technology platform in space, announced that it is on the brink of a historic moment as the company prepares for its biggest-ever “burst test” of Sierra Space’s inflatable, expandable space station technology.

This groundbreaking endeavor marks a critical step in Sierra Space’s co-development of Orbital Reef with Blue Origin, as the company plans to stress test – for the first time in history – a full-scale version of its LIFE habitat structure and bring the unit to failure under pressure. LIFE is constructed of high-strength “softgoods” materials, which are sewn and woven fabrics – primarily Vectran – that become rigid structures when pressurized on orbit. To date, Sierra Space has conducted five stress tests on subscale test articles; this next one will be 18x larger – nearly 300 m³ of pressurized volume.

Scheduled for December 2023 at the NASA Marshall Space Flight Center in Huntsville, Ala., the Ultimate Burst Pressure (UBP) test is expected to provide Sierra Space and the Orbital Reef program team with critical data in support of NASA’s softgoods certification guidelines. The over-pressurization to failure during the test will not only demonstrate the habitat’s capabilities but also open avenues for structural enhancements.

Sierra Space’s expandable space station module technology is highly scalable and flexible to all existing and planned launch vehicle fairing sizes. The softgoods structures launch packed inside conventional rocket fairings – 5m, 7m, 9m and beyond – inflating to capacity on orbit. Low-volume launches become high-volume space stations. The module volume will always be the square of its expansion diameter. For example, with a 2.5x expandable configuration, the volume would be 6.25x of a rocket fairing.

“Sierra Space’s inflatable space station module technology offers the absolute largest in-space pressured volume, the best unit economics per on-orbit volume and lowest launch and total operating costs,” said Sierra Space CEO Tom Vice. “Having the best unit economics positions Sierra Space as the category leader in microgravity research and product development – providing customers with the most attractive return on their investment.”

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