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Quantum fluctuations in space, science, exploration and other cosmic fields... served up regularly by MSNBC.com science editor Alan Boyle since 2002.

Alan Boyle covers the physical sciences, anthropology, technological innovation and space science and exploration for MSNBC.com. He is a winner of the AAAS Science Journalism Award, the NASW Science-in-Society Award and other honors; a contributor to "A Field Guide for Science Writers"; and a member of the board of the Council for the Advancement of Science Writing.

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Inside the spaceship factory

Posted: Thursday, July 20, 2006 11:59 PM by Alan Boyle

On a 50-acre spread in North Las Vegas, near the intersection of Warp Drive and Skywalker Way, the prototypes for future space stations are being built from strips of fortified fabric, supertough inflatable skin and lattices of metal.

Today a gaggle of journalists and space entrepreneurs got a rare look inside Bigelow Aerospace's industrial-park production facility and mission control center, just a week and a day after the company's launch of its Genesis 1 orbital test module. We were treated to three and a half hours of talk and tours, led by billionaire Robert Bigelow and his top engineers.


Alan Boyle / MSNBC.com
Security officer Wayne Leslie welcomes visitors to Bigelow Aerospace.

With the success of Genesis 1, Bigelow has become much more willing to show off the facilities he's built as part of his $75 million space investment. There are limits, of course: I had to delete one of my pictures under the watchful eye of a security guard because I pointed the camera in the wrong direction. But we ended up with plenty of pictures, and plenty of good quotes from "Mr. B" during a question-and-answer session in the company's hangarlike Building A. Here's a sampling:

Bigelow has been surprised by just how successful the Genesis 1 mission has been - a mission that was the first orbital test of an inflatable spacecraft that represents the first step toward private-sector space stations. The 4-foot-wide, 14-foot-long module was launched atop a converted Soviet-era intercontinental ballistic missile from a Russian military base, then inflated to twice its diameter, just as planned.

"I think I was the most 'doubting Thomas' in the company," Bigelow told our group of about two dozen visitors.

"I'll second that," chimed in Genesis program manager Eric Haakonstad.


Laura Rauch / AP
The Genesis team meets the press. From left: Boris Rubanovich, Mark Pierson,
Jay Ingham, Robert Bigelow, Eric Haakonstad, Allison Manion, Roger Gonzales.

The day of launch was a nail-biter for the Genesis team. There was an hours-long gap between liftoff and confirmation that the spacecraft was in its proper orbit. "That's when I got nervous," Allison Manion, who led the mission control team, recalled. She was up for 23 1/2 hours on that first day.

But as the days wore on, the news just got better and better:  Haakonstad said the high-speed communication link has been working like a charm. "I believe this will be the longest TCP/IP wireless link in existence," he observed.

About 500 images have come down from orbit in the first week, said Bigelow Aerospace's Roger Gonzales. Only a few of them have been released, however.


Laura Rauch / AP
Science editor Alan Boyle is silhouetted against display screens in the darkened
mission control center for the Genesis 1 spacecraft.

Now that the team has had a chance to make a detailed assessment of the spacecraft's health, engineers figure that the module could last even longer than the three to seven years they estimated before the launch. Haakonstad said Genesis 1 could hang around for as long as 13 years in orbit, providing insights into just how durable the inflatable skin can be.

The schedule calls for launching a second Genesis by the end of the year. Genesis 2 should have a better flight control system, and Bigelow said it's designed to carry about 18 cameras, as opposed to the 13 on Genesis 1. The second spacecraft will start flying other people's stuff (and sending video of that stuff floating in zero-G) for as much as $295 a shot - marking the project's first significant revenue stream.

"What we're trying to do with this first spacecraft is draw attention to the second spacecraft," Haakonstad said.

After Genesis 2, Bigelow Aerospace will step up to its Galaxy-class prototypes, which will have twice as much pressurized volume as the Genesis craft.

The aim is to work up from the one-third-scale Genesis to a full-scale, 330-cubic-meter Nautilus module that will have as much space as a three-bedroom house (and as much space as the international space station in its current configuration). Such modules can be linked together, using the same standards as those for the international space station. In fact, a Nautilus module could be hooked up to the space station if desired, said Mark Pierson, manager for vehicle integration and test.


Alan Boyle / MSNBC.com
Mission controllers Tom Londrigan and Matt Boyd monitor Genesis
1. The spacecraft passed right over Las Vegas during the tour.

Bigelow said "we feel we are ahead of schedule" on his plans to have a commercial space complex in orbit by 2015. The current projection is that a Bigelow-built orbital station could be ready in the 2010-2012 time frame, assuming that other companies can develop safe, economical and reliable rockets to put payloads and people into orbit by that time.

And beyond that, Bigelow said "we definitely have a lunar architecture in mind." Inflatable modules could be assembled en route to the moon, plunked down on the lunar surface, then covered over with moondirt to provide protection against radiation. Although such an application is probably years down the road, Bigelow and his engineers are already laying the groundwork here on Earth.

"We're going to be testing that, we hope, this year over one of our steel simulators," Bigelow said.


Alan Boyle / MSNBC.com
A full-size air bladder for a Nautilus module stands inside Building A.

We didn't get to see those simulators today, but we were treated to a tour of other Bigelow facilities by Haakonstad, Pierson and Jay Ingham, design team leader. We started out in the darkened mission control room, in a walled-off section of Building A, where two or three controllers monitored spacecraft telemetry. On the walls, giant TV screens displaying Genesis 1's ground track and not-yet-published pictures of the spacecraft interior (including a snapshot of cockroaches inside a life-support experiment).


James Oberg / MSNBC.com
Erik Haakonstad and Alan Boyle size up
a Genesis-scale test module.

Then we headed out and around a corner to the other half of Building A, past a fully inflated test bladder for the future Nautilus module.

When I tried to take an overall shot of a machine shop, a security officer quickly called a halt - and insisted on watching as I hit the "delete" button for the offending image.

But it all ended with good humor and a handshake, and we had our picture taken with our arms around each other's shoulders.

Other highlights included:

  • A close-up look at Genesis test modules sitting in the machine shop. One module was double-wound with straps that held a partially inflated bladder in place. When I banged my hand against the side, it thumped hard as if I were playing a drum.
  • A visit to the 26-foot-deep outdoor pool where test inflatables are immersed for stress testing. The pool was only partially filled today, but the blue water looked positively inviting in the 90-degree-plus heat.
  • A stop at Building B, where Bigelow maintains a museum of module mockups, artist's conceptions dating back to 2001 - and a full-scale mockup of three linked Nautilus modules. We climbed inside the complex, outfitted for three levels of living space. Each level had a lattice of straps as a floor - which would serve better than a solid floor for handholds and footholds in zero-G, Haakonstad said.

But where was the real Genesis 2? Well, Haakonstad said that spacecraft was still taking shape, and the integration facility where engineers are working on the actual items for flight is in another section of Building B - a section that was off-limits to us. Even now, some secrets have to remain secrets.

"We're trying to protect the very valuable stuff that we're working on," Bigelow told us.

Stay tuned for more about Bigelow Aerospace, once I put the rest of my notes in order. And for a look at yet another nexus of space commercialization, check out this archived report on SpaceX's rocket factory.

Update for July 21, 6:50 p.m. ET: Due to a publishing glitch, our presentation of the first videos from Genesis 1 was out of commission for the past couple of days. I just wanted to pass along the word that the video is back in service. Sorry about the initial failure to launch.

Also, you'll find additional perspectives on the Bigelow Tour from Clark Lindsey at RLV and Space Transport News, Jeff Foust at Personal Spaceflight and Leonard David at Space.com.

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Comments

Alan: Excellent coverage, as usual.
Amen to the excelent coverage. Look forward to reading more from the SFF conference.
Do they plan on doing any on-orbit rendezvous and/or docking of the prototype modules?
These news are more than just great. It is exciting!
I hope to live to see some of these commerical develoments.
Hooray! It's not news that innovation is the key to success in private enterprise. Hence the need for these guys. As with SpaceshipOne, when you don't have government billions, you must find alternatives (to billion dollar spacecraft). Thanks for sharing this with those of us on the sidelines.
Wow, I feel like I was there WITH you! Uh...
Wait a minute -- I was -- and it was a great event, the whole team, gracious and hospitable, opened up enthusiastically and went the extra million miles to help us understand their experiences and backgrounds and hopes -- and now it's our turn, to help pass on those insights.
What about a new Shuttle?  The other ones are over 20 years old.
It is exciting to hear that Bigelow has thought of using his inflatable modules in creating a subterranean Moon based structure. I hope the testing he plans for such a structure goes well.

Is Bigelow Aerospace planning on attaching one of its inflatable modules to the ISS at some point in the future? This article clearly states that it is possible.  
It is the NEW Wright Brothers' bicycle shop!  Only much larger, air conditioned and obviously well protected.

I wonder if a hundred small modules linked together could be as accomodating as one large module?  Or if the larger Bigelow module could be wrapped with smaller modules, the same way accessories are clipped onto a utility belt.  In this way the smaller modules would provide the additional benefit of further insulating the large module against impact damage by space-borne debris.
Rupe: The future of space is important to our collective human civilization, in my opinion. Practical space development will come from business just read Heinlein.
Bigelow is the next Howard Hughes and Sir Richard Branson, taking his own $$$ and leading the charge into the next frontier.  While there are hundreads of people lending a helping $ hand to humanitarian causes (which is all and good), this is a guy who has a vision for something bigger.

Other useful applications:
-  an escape pod for the Internation Space Station
-  for NASA's plan to go to Mars, have the Mars-o-nauts inflate one for the trip there & back .. and pack one for the surface mission.
-  send one packed with the best things man-kind has to offer on a one way trip out of our solar system.
What a boring blog I will leave: I just want to say thank you to all who have had a hand in all and everything space related. I don't have much time left here on Earth, so before I can see space for myself soon enough, I cry with joy when I read/view stories such as the one listed above. Good luck and God Bless you all. Pamela.
Alen: Thanks for the beautiful article on our facility. It was a great pleasure having you there. Hope to see you again soon.

ohhh one more thing....thank you for deleting the photo
Any idea how resilient these inflateables will be in terms of high speed particles? Small asteriods, space junk, or even a common bolt travelling at 50,000 mph seem to me to be quite a hazard for inflateables.  Any comments here?

Thanks

Clay
This is the type of work that can save us as a species from any number of disasters we are currently struggling with.. People need to think about volunteering thier time and expertise to efforts of this nature (google up the other private space contractors).. Please see my blog (I have a few on that site, but this is one of the most important ones)..
Clay Perreault,
  Not sure any space station (or even a tank for that matter) can hold up to a mere bolt traveling at those speeds.  Composite materials are a pretty interesting study in and of themselves.  They can be tougher than aluminum or steel and yet can have some flexibility.  Space debris in general will have to be addressed eventually with some kind of garbage-gathering satellite!  

We at the Florida Space Research Institute are very proud of our former-intern Alli for her contribution to Bigelow's success. Congratulations to all of you on your success!

Larry Hughes
WOW

I am the same age as Sally Ride and postponed a career in phyics.  I could be an early customer or work on helping you get there.  

All those difficult college classes may yet pay-off.

Nancy
To the comment on impacts of objects at 50,000 mph, ANYTHING being hit by a bolt moving that fast is gonna feel it, even the ISS or the Shuttle would be compromised by such an impact.  Given the physics at work, it wouldn't matter whether you were behind carbon-carbon panels, steel plating, or an inflatable, an impact by reasonably hard object at that velocity is going to cause a REAL bad day.

Its like comparing a crash in a blimp versus a crash in an airplane.  Either way, sucks to be you.
Indeed. This is the logic behind what the military describes as Kinetic Energy Weapons (of which bullets are the oldest sort), involving non-explosive projectiles at several tens of thousands of feet per second.

However, knowing that some sort of impact is probable given enough time, I can easily understand how Bigelow will want to know precisely *how* their inflatables respond to such impacts and punctures, wether holes will resist tearing and enlarging as much as they expect, and determining if hypothetical occupants would have time to evacuate to another module.

We've already seen the need for such concerns, since the Progress collision with Mir required a similar evacuation and isolation of one of its modules.
There is a difference, however, between a balloon getting punctured and a Thermos.

So the real question the OP wants answered is: what will keep the structural integrity intact in the event of a puncture.  To that I would speculate, isolated, redundant bladders.   In fact if you did have a two layer hull with inflatable bladders in between, I might even imagine the punctured bladder being able to plug up the hole on its own.

It would be interested to see just how they built one of these.
I am an amateur astronomy buff with lots of ideas on what can improve and protect inflatables. one cheapway (only in theory) would be to use natural elements for protection..example...heated water mixed with an antifreeze agent to cover the primary outer skin of the ship will first absourb impacts and save the inner skin of the module. second,the outer skin should be made using multiple layers of very flexible materials like kevlar in order to stop particles travelling at high speeds and the water inbetween will serve as multiple shock resistance like when firing a gun in water. in theory the kevlar should reduce or even stop the particles and the water mixed with antifreeze so as not to solidify should protect the inner craft by slowing the momentum of the particles. in multiple layers this application will and should if tested properly avoid any particle upon impact to be either stopped or be absorbed within the multiple layers of kevlar filled with water.other materials like spider silk woven in different patterns in multiple layers using water as a natural absorber should in theory work......
We pollute every single place we tread so why should space be different.

One reason to explore space is to find other planets to ruin.

If there were a galactic green peace they would be orbiting the planet in protest....

Don't mistake my views as anti space exploration...but, one would think that the best minds would find a way to clean as they go....
Inflatables may possibly become an answer to the problem of impacts between space vehicles and high-speed debris while in orbit.  Granted, there are multiple variables involved in calculating the outcome of the impact (mass, speed, density, structure,...), and most likely no one answer will work for all impact scenarios.  But think about it, if an object collides with a rigid surface, the energy tranference from the collision will result in some type of deformation of both objects (aka. most likely a hole in the vehicle).  But what if that same object collides with a resilient and somewhat elastic surface, a portion of the kinetic energy from the collision will be dissipated across the surface of the fabric (aka. heat & elongation of the fibers) during the deceleration of the debris object.  If the debris can be decelerated before the material gives way, we have no hole.  Same concept as kevlar fabric in a bullet proof vest.  I'm not saying they have the perfect concept, but I do believe they are on the right track of finding an answer to the problem orbital collisions with "bolts", trash, and other cosmic "debris".  Comments?  
I have read all the comments,  the great ones and the ones that remind me that there are really some fools out there.

WHAT I wanted to say is thank God that there are true men of vision out there like Robert Bigelow.  He has taken part of is fortune and is putting it toward a vision that could help us all.  He has apparantly surronded himself with very brillant people that are helping him to realize success in his venture.  Now let us hope that the government does not try to smother this venture.
The water tank was only partially filled because it did not have any test item submerged in it. A full tank would only overflow when a large object was submerged for testing.
Excellent article. I was entralled at the story and it conjoured up all sorts of ideas in my head any way.
Kudos to Mr. B and kis crew. I look forward to seeing where this takes us from here.
How do they propose to SpaceTourists to their station? Is there some sort of Bigelow shuttle in the works or are they partnered with another company?
 Well I am just a student of aerospace but from what I read its and excellent idea!  BUT also from what I read I think it has a very basic design flaw that could make it very unsafe for habitation! While they seem to have their program together and running smoothly they would have to do a different test before I would bet my life inside of one. If the proper minor design change is made and the test is good then it would be a definate breakthru in space exploration, but for now I they might have invented the a very useful space container for storing and moving supplies and such.  He needs to step back and think of a "What If" before thinking it can be occupied as designed.
Onward ... upward ... outward.
My granddad saw travel go from the horse to a man on the moon ... and I'm real sad that by the year 2000 space travel was not farther along than it is.
So ... GO FOR IT!
Hi Allen - Great report.

I wonder how long the long chain molecules in Genesis's fabric will stand up to the radiation of the space environment. For lunar use there is a good way around this, so Mr. Bigelow's investment may not be entirely lost.
That is all very good and very real, but whatever happened to the idea of using the shuttle fuel tank as a platform. At the time it was considered it was considered practical to get them the rest of the way into orbit. They are huge and fairly structurally strong. What happened to that idea?
Remember, everything is relative. So in space, your capsule will be going pretty fast soon, probably negating the speed of half of the particles bent on hitting your spaceship. And the vastness of space will probably lower the odds of getting hit by a random bolt to an extremely unlikely number.
Just an idea. There is a sort of material, which is light and has both mechanical and thermical resistance, compared to its weight. Light gels, like aerogel or seagel. Why not to inflate the modules of a station and begin to circulate the ingredients of the gel in order to saturate the gas inside the module. With a microwave generator, would be possible to cook the mixture and turn it into gel. There are many possibilities from this point on. First, depending of the chemical afinity of gas used to fill the blocks of the modules(afinity with the gel), and because of it being traped into the material, it would be safer, mechanicaly, and less prone to accidents. Nobody would like to be inside a ship or station that can go flat after meeting a micrometeorite. Second, depending of the mix of gases would be possible, by applying an electromagnetic field of proper frequency, to ionize the gas and make it an effective barrier against some electromagnetic radiations found in open interplanetary, or interstellar space. (If somebody gets interested, please, I'd like to have my name mentioned in a patents application, if there is none for this yet, and get a provision of one percent on the applications). Want more ideas?
I'd think that a decently sophisticated radar system could spot any incoming object large enough to be dangerous, station computers could calculate trajectory of the object and identify which areas of the station were likely to be compromised, and trigger a warning system of some sort. IE, bolt is spinning towards the station, going to pass through a habitation module at an angle, penetrating three rooms. Warning buzzers alert occupants, who are (just like a plane with oxygen masks, or apartment fire drills) instructed to exit their rooms...of course, an emergency patching crew has already been dispatched from the maintenance ring... No problem. Wow...I LOVE BEING ALIVE NOW!!!
Read more about Fence
I would like to see Bigelow Aerospace mass produce their inflatable modules and connect them to create a large rotating space station like on 2001 Space Odyssey... when will we see habitats in space with gravity produced by rotation? Also set up a system where people can leave Bigelow Aerospace their estates to further the cause.

Cheers;
Mark Klimaszewski, TX.
are there any spaceships (or metals) that are resistent to space junk (debris). if there are please contact me soon.  
Is there any water on spaceships? Can there be any water on spaceships?.


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