10/2/2014
1
Mr. Jess Sponable
Program Manager
Program Overview for COMSTAC
16 September 2014
Experimental Spaceplane (XS-1)
First Step Toward Reducing the Cost of Space
Access by Orders of Magnitude
Distribution Statement A – Approved for Public Release, Distribution Unlimited
U.S. Launch – A Growing Problem
2
• 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
United States
Foreign
40m
50m
60m
70m
Evolved ELV
~8 DOD flts/yr
> $400M/flight
Pegasus
Minotaur
Antares
~ 1 flt/yr
~$55M/flt
Falcon
~5-15 flts/yr
~$54-128M/flt
Foreign Boosters
~60 Commercial & Gov��t flts/yr
> $120M/flight
Distribution Statement A – Approved for Public Release, Distribution Unlimited
10/2/2014
2
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
Experimental Spaceplane (XS-1)
Step One to Routine, Low Cost Access to Space
3
Open Design Space
Artist Concepts
Up To Industry
Propulsion
Propellants
Configuration
Technology
CONOPS
Technical objectives
•
Reusable first stage
•
Fly XS-1 10 times in 10 days
•
Fly XS-1 to Mach 10+ at least once
•
Launch demo payload to orbit
•
Design for recurring cost �� 1/10
Minotaur IV
(< $5M/flight for 3,000 – 5,000 lbs to LEO at 10+ flts/yr)
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XS-1
F-15
Booster
Engine
2 Merlins
GLOW (K lbs)
223.9
MECO (K lbs)
47.4
Usable LOX/RP (K lbs)
176.5
Isp (vac)
310
Stage PMF
0.84
Upper Stage
GLOW (lbs)
15.0
Isp (vac)
336
Stage PMF
0.9
Payload (K lbs)
3.0
0
100
200
300
400
500
600
A
ltitu
d
e
, K
ft
Downrange, nmi
2-Stage Vehicle (GLOW-223.9K lbs)
Booster (2-Merlins)
Propellant = 176.5K lbs
ISP (vac) = 310 sec
PMF = 0.84
Upper Stage (GLOW-15K lbs)
ISP (vac) = 336 sec
PMF = 0.90
Staging:
Time = 169.9 sec
DR = 71.9 nmi
Altitude = 237,155 ft
Mach = 10.8
Payload = 3,025 lbm
100x100 nmi
28.5 deg Inclination
700
600
500
400
300
200
100
0
61.6 ft
Notional Government Reference X-Plane
One of Many Possible Industry Solutions
Expendable stage ~5%
of stack weight
4
Mach 10 staging with small upper stage (shown)
Alternative would be Mach 5 staging with larger upper stage
Distribution Statement A – Approved for Public Release, Distribution Unlimited
Artist Concepts
10/2/2014
3
XS-1 Phase I Awards
5
• Phase 1 system awards
✓ The Boeing Company working with Blue Origin
✓ Northrop Grumman working with Virgin Galactic
✓ Masten Space Systems working with XCOR
• 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
Artist Concepts
Artist Concepts
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
Phase 1- Initial
Design
- Risk Reduction
- System Design
Integration
Phase 2 – Final
Design Fabrication
and IA&E
- Reusable aircraft
- Upper stage
Phase 3 - Flight Test
Campaign
- Transition
Opportunities
PDR
Phase 1
Phase 3
KO
XS-1 Design
Airframe
Fab
IA&T
IDIQ
Upper Stage Integration
1st
Flight
Orbital
Flight
Select
XS-1 prime
XS-1 Planned Schedule
Propulsion
CDR
USAF, NASA, Industry
Technology Transition Off-Ramps
XS-1 Design
Phase 2
6
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10/2/2014
4
NASA Programs
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,
MAV, Copper Canyon
Have Region
National Aero-Space Plane
$70M
SAC SON 7-79
AFSPC MNS 6-84
$35M
SSTO Studies
$3,000M
DOD DC-X Program
AFRL Ground Tech Maturation
MNS 2-01
PGS
AFSPC
CONOPS
MNS 1-01
Spacelift
SUSTAIN
ICD
X-40/X-37
$200M +
Orbital Test Vehicle
Long Spaceplane History
7
Long USAF Push for Aircraft-Like Access to Space
Distribution Statement A – Approved for Public Release, Distribution Unlimited
Artist Concepts
Legacy of Past Programs
$3 billion
Past programs over-specified the problem (SSTO, scramjet, heavy lift,
crewed, etc.) AND relied on immature designs and technology (TRL 2/3)
VentureStar
Initial Goals
(requirements)
NASA human rated
Payload – 65K lbs
AF crewed
Payload < 10K lbs
SSTO, scramjet powered
Aircraft-like ops, fast turn
NASA human rated
Payload - 65K lbs
SSTO, rocket powered
Aircraft-like ops, fast turn
Technology
(at start)
TRL ~3 and immature design
New LOX/LH2 SSME
Unproven materials/TPS
Toxic OMS/RCS, etc.
1960s/1970s technology
TRL ~2 and immature design
New LS/RAM/SCRAM/rocket
New materials/structures
New LOX/LH2 tanks
New hot structure TPS, etc
TRL ~3 and immature design
Mod LOX/LH2 aerospike rocket
New composite structures
New metallic TPS
New LOX/H2 tanks, etc.
Approach
Expendable launch (SRB, ET)
Operational after 4 flights
Evolved to ��space station��
X-Plane first
Incremental flight test
X-Plane first
Incremental flight test
Outcome
Successful flights
Very expensive with
ground ��standing army��
Never flew
Design never closed
Technology not available
Never flew
Design never closed
Technology not available
Space Shuttle
NASP
NASP
8
Artist Concept
Distribution Statement A – Approved for Public Release, Distribution Unlimited
Artist Concept
10/2/2014
5
Responsive
Ops
Affordable
Composite
Airframe
��Trimmed��
Full Envelope
AG&C
Integrated
Systems Health
Management
Affordable
Infrastructure
Thermal
Protection
Systems
Cycle of Prep, Launch, Recovery, and
Turnaround within Single Day
Integrated
RLV Subsystems
Ongoing Long Term
High Ops Tempo Propulsion
Low Cost
Upper Stage
+
Autonomous
Operations
FOCC
Design
Integration
Aircraft-Like Ops
250k lbf. thrust Brassboard Demos
Off-the-Shelf propulsion
available for demo
What Has Changed?
20 years of investment �� Technology mature & affordable
9
Artist Concepts
Distribution Statement A – Approved for Public Release, Distribution Unlimited
XS-1 Goals
1. Break cycle of escalating space system costs
• Seeking path to affordable space
• Would enable disaggregation &
resiliency strategies
• 10X lower launch cost
changes how spacecraft
are built
2. Enable new types of aircraft & test capabilities
• Space access aircraft �� Global ISR and protection
• Affordable hypersonic aircraft �� Low parts count & CTE structures/TPS
• Hypersonic testbed �� boost-glide systems & hypersonics
3. Enable residual capability
• ORS Launch �� single smallsat or constellations for rapid employment
• Support growth options including near-term modular options
10
Blk I: Sat $43M, Launch $47M
GPS Blk III
Sat $300-500M, Launch $300M
Modular Bi-mese
One
Example of
Today��s Cost
Growth
Spiral
Smaller satellites
Shorter lifetimes
Fly more often
More failure
tolerance
Less redundancy
More frequent tech refresh
Path to
Affordable Space
Increasing
obsolescence
Bigger satellites
Greater complexity
Longer development
Fewer satellites
Longer life
Greater redundancy
Artist Concepts
Artist Concepts
Artist Concepts
Artist Concept
Distribution Statement A – Approved for Public Release, Distribution Unlimited
Artist Concept
Artist Concept
Artist Concept
Artist Concept
Artist Concepts
10/2/2014
6
Airborne Launch Assist Space Access
(ALASA) aims to enable responsive
launch of 100 lb payloads from existing
globally distributed airfields to enable
next-generation tactical missions
The Experimental Spaceplane (XS-1)
reusable vehicle capability would
extend this capability to 3,000 lb
payloads with ��aircraft-like�� access to
space at 10X lower costs
Collectively the space portfolio is supporting responsiveness and cost reduction
of launch through ground-based systems.
All images are artist��s concept
DARPA Leadership Perspective:
Attack the cost equation
Distribution Statement A – Approved for Public Release, Distribution Unlimited
11
Artist Concept
Artist Concept
Challenges to Achieving Lower Cost
XS-1 would complement heavy Falcon & EELV payloads
1
10
100
0.01
0.1
1
10
100
Conventional
Launch Vehicle
Trendline
Delta II
Variants
Small Solid
Launchers
S
p
e
c
ific
C
o
s
t (k
$
/
lb
m
)
Payload to LEO (klbm)
ALASA
EELV
Variants
XS-1
Trade Space
• Design and system integration
enabling ��aircraft-like�� operations
• Light weight/high energy airframe,
high propellant mass fraction
• Durable thermal structures/
protection, -300oF to +3,000oF
• Reusable, long life & affordable
propulsion
Note: Data extracted from FY12 PE/BPAC data, Excludes AFSPC payroll at launch sites and base O&M
ELV Launch Cost Breakdown
Technical Challenges
Facility,
support,
launch
complex,
$1.32
Launch
Vehicles,
$1.44
Mission
Assurance,
$0.20
Falcon 9
12
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10/2/2014
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Facility,
support,
launch
complex,
$1.32
Mission
Assurance,
$0.20
ISHM
Clean pad
Few Facilities, Small Crew Size
Autonomous Ops
Incorporate ��-ilities��
Complex
to Simplex
Today��s
Launch Complex
Launch Site/Base Manpower Comparisons
M
a
n
p
o
w
e
r/
A
ir
c
ra
ft
Goal
AUTONOMOUS VEHICLE, NO SOLID BOOSTERS, SIMPLE
STAGE, etc.
SPECIAL GSE
OPS FLOW MGMT
AUTOMATED CHECKOUT
ON BOARD SELF TEST
ON BOARD HEALTH MONITORING
PAYLOAD STANDARD INTERFACES
INCREMENTAL FLIGHT TEST
Delta II Baseline Data
0
100
200
300
400
500
600
T
u
rn
a
ro
u
n
d
(
h
o
u
rs
)
Design for Rapid Turn Reduces Manpower
Goal: Design and System Integration
Enable ��aircraft-like�� operations
13
Distribution Statement A – Approved for Public Release, Distribution Unlimited
Goal: Design Integration
��Clean Pad�� Aircraft-Like Operations
• Aircraft-like CONOPS
– Clean pad - rapid throughput
– Ops Control Center – like aircraft
– Containerized payloads
• Aircraft GSE/Facilities where practical
– Hangars, not specialized buildings
– Standard interfaces/processes
– Automated ops, propellant & fluid loading
CLEAN PAD CONOPS
Rapid Throughput, < 24 hrs on pad
OPS CONTROL CENTER
Small 3 Person Ops Crew Size
Flight Manager
(FM)
Deputy FM Crew Chief
• 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
– Adaptive GN&C – safe, reliable recovery/abort
14
Artist Concepts
Distribution Statement A – Approved for Public Release, Distribution Unlimited
10/2/2014
8
Goal: Light Weight / High Energy Airframe
High Propellant Mass Fraction (PMF)
NASA
Open-Core Tank
in Fabrication
Design tank / airframe structure to enable high PMF/ V
USAF
Monocoque Tank in
Test
��V = ISP * g * ln
1
1 - PMF
Launch
Vehicles,
$1.44
Mission
Assurance,
$0.20
Tank/Structure Integration
✓ Integral load bearing structure
✓ High PMF key to performance
✓ 10X fewer parts & lower cost
✓ Reusable vehicle cost would be
amortized rapidly ��
Composite
Structures Reduce
Weight ~30%
aka
X-55
Affordable Structure
Unit Cost
No. Flights
15
Distribution Statement A – Approved for Public Release, Distribution Unlimited
Goal: Durable Thermal Structures / Protection
-300 oF to +3,000 oF
Emerging Thermal Structures
Composite Hot Structures
Aircraft
Hot Wash
Structures
Mechanical Atch
Quick-
Release
Fastener
AFRSI and CRI
Leading Edges
ACC, C/SiC, TUFROC
Many Thermal Protection Options
Space Shuttle Post-
Flight CMC/TUFI
Tiles
Launch
Vehicles,
$1.44
Fibrous
Opacified
Insulation
Honeycomb Composites
500
1,000
1,500
20
40
60
80
100
Time (sec)
H
e
a
t
R
a
te
(
B
T
U
/
ft
2 /
s
e
c
)
13.3K
BTU��s/ft2
51K BTU��s/ft2
<2K BTU��s/ft2
How you design & fly is key!
Reentry AOA – 30o
Reentry AOA – 70o
Mach 10 suborbital
POST Results Ref
Heating on 1 ft
Radii Leading
Edge
16
Distribution Statement A – Approved for Public Release, Distribution Unlimited
10/2/2014
9
Goal: Reusable, Long Life and Affordable Propulsion
Multiple Options – Design Integration Challenge
Merlin
Commercial
Rocket
Multiple Affordable Propulsion Options
NK-33
Stockpiled
Russian
Rocket
SSME
Space
Shuttle Engines
Ventions
STA
XCOR
M
O
D
U
L
A
R
R
O
C
K
E
T
Launch
Vehicles,
$1.44
Mission
Assurance,
$0.20
✓ Use existing propulsion with mods for
• Long life �� rapid call up/turnaround ��
deep throttle
• High reliability �� historically, most
launch failures caused by propulsion
✓ Design as Line Replaceable Unit
• Rapid remove and replace
• Support high ops tempo flight rate
© Space Exploration
Technologies
© XCOR Aerospace
17
Distribution Statement A – Approved for Public Release, Distribution Unlimited
Flexible Launch & Landing Options
Fly from Anywhere, Anytime
Delivers affordable, routine space access - On path to global reach capability
Fully Reusable
Vehicle
Step One: S-1
3-5K Payload
10X lower cost
Enabled Futures
Global Reach Capability
100X lower cost
Hi Speed
Aircraft
OV-1 Derived Capabilities
18
Fighter Sized Demonstrator
Expendable
2nd Stage
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10/2/2014
10
• Core capability > 3,000 lbs to LEO
✓ Option: Grow capability with modular launch
• Payload disaggregation could shrink sizes
✓ Downsize & modernize payloads
✓ Single payload siimplified spacecraft
• Stage disaggregation would grow effective
payload
✓ Launch satellite payloads separately
✓ Dock stage on-orbit with satellite
• Grow launch markets
• Capture / recapture commercial launch
• Enable new military / ORS capabilities
• Hypersonic testing / release of free-flyers
XS-1 Capabilities Would Evolve Over Time
Deploy mated satellite &
stage
Modular Bi-mese
Solar Electric
Propulsion
Autonomous Dock of
Chemical Stage/Sat
5
Free Flyer
Hypersonic Test
Downrange Constant Q Flight Profile
B
u
rn
O
u
t
M
a
ch
N
o
.
10
Boost Glide
Disaggregated
Satellite Missions
Distribution Statement A – Approved for Public Release, Distribution Unlimited
19
Artist Concepts
• ��97-��99 spike due to Iridium and Globalstar
• Lost commercial opportunities
• Commercial launch migrated overseas
�� $Billions in lost revenue
�� Grew cost of DOD launch
• New constellations hard to finance
�� Teledesic
• Potential to leverage commercial sector
• Missions potentially enabled by XS-1
• USAF ORS & ��disaggregated�� satellites
• Recapture commercial launch
�� Historical avg of 3-5 launches/yr at 5,000 lbs
�� Projected market much higher
Potential XS-1 DOD and Commercial Satellite Markets
Responsive launch of 3 to 5K lb payloads
0
10
20
30
40
50
60
70
1993 1995 1997 1999 2001 2003 2005 2007 2009 2011
N
o
. S
a
te
llit
e
L
a
u
n
c
h
e
s
C
a
p
tu
re
d
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.
XS-1 Capture of Historical
U.S. Launches: 1993 to 2012
10,000–15,000 lbs
5,000–10,000 lbs
Satellite/Stage Mass
< 5,000 lbs (XS-1)
0
200
400
600
800
N
o
. P
a
y
lo
a
d
s
Worldwide Projected Payloads: 2013 to 2022
Mass (lbs)
Note: Data from Teal Group,
Aerospace America, June 2013
> 70 Launches/yr
© Space
Exploration
Technologies
© Blue Origin
© XCOR Aerospace
© Virgin Galactic
© Stratolaunch
Systems
© Teledesic
20
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10/2/2014
11
• Captive carry experiments
• May Limit Q and thermal testing
• Propulsion (RAM/SCRAM/Turbine)
• Airframe/Structures
• Thermal Protection
• Release free-flyer experiments
• Unpowered constant Q reentry
• Long test time vs. ground test
• Aerodynamic & thermal test
• Laminar flow/boundary layer transition
• Controls/avionics
• Powered test vehicle
• Longer flight tests
• Useful test data limited only by scale
and cost
Constant Q Unpowered Glide
from Engine Burn Out
Multiple Test Options
Projected Cost of Flight Test < Many (Not All) Ground Tests
Test of component/systems ♦ RAM/SCRAM/turbine ♦ Boost-glide vehicles
5
10
200
Constant Q Test Time
~90 sec
~120 sec ~300 sec
400
600
800
Downrange (nm)
15
B
u
rn
O
u
t M
a
c
h
N
o
.
Free
Flyers
Captive
Carry
XS-1 Could Facilitate Next Gen Hypersonics
21
Artist Concepts
Distribution Statement A – Approved for Public Release, Distribution Unlimited
✓ Robust DOD and commercial launch industry with ideas
✓ Growing small satellite industry building low cost satellites
• Commercial
• Military
• Civil
✓ 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
XS-1 Transition Path Would Require Proactive Industry
© Space Exploration
Technologies
© Blue Origin
© XCOR
Aerospace
© Virgin
Galactic
© Stratolaunch
Systems
© Sierra Nevada
Corporation
© Skybox
Imaging
© Space
Exploration
Technologies
© Teledesic
© Globalstar
© Orbital
Sciences
22
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10/2/2014
12
Commercial
Capability
Commercial Launch for
ORS, AF & Intel
Many Transition Options
Aircraft-Like operability
National security global reach
architectures
Proposed XS-1 Program
F-15
(Size Ref)
Build
Mach 1-10
Bare Base
CONOPS
Flight Test
Demonstrate
Payload to LEO
Enable AFSPC Full Spectrum
Launch Capability
Near Term
Transition
Options
Space
Access/ISR
Vehicle
Hypersonic
Testbed
Stepping Stone to Future Capabilities
Technology scalable to future capability
XS-1
Point-to- Point
Boost-Glide
Transport
23
Artist Concepts
© Stratolaunch
Systems
© Virgin
Galactic
Distribution Statement A – Approved for Public Release, Distribution Unlimited
Artist Concept
M
a
ch
N
o
.
XS-1
Flight Test
Mach 10 Would Validate Critical Access to Space Technology
XS-1 will mature technology for 1st Stage AND fully reusable flight to space
24
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13
• 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
XS-1 Seeks to ��
Trailblaze next generation commercial space ��
�� technology, flight envelope, regulatory, new markets, etc.
Distribution Statement A – Approved for Public Release, Distribution Unlimited
25
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
Summary
Several Notional Concepts
26
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Artist Concepts
Artist Concepts
Artist Concepts
Artist Concepts
Artist Concepts
10/2/2014
14
www.darpa.mil
27
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