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On today's episode, we are getting
into the latest space news, including SpaceX

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works on a starship fuel tanker prototype
while waiting for a test launch date.

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NASA announces an expansion plan for the
Kennedy Space Center that could include a new

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star factory, and Sierra Space improves
on their inflatable habitat tech. This is

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the space race. While SpaceX waits
for the bureaucratic red tape to clear for

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their next starship test flight, the
engineers at Star based Boca Chica are not

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being idle in a very typical fashion. The SpaceX team is simply continuing to

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work on construction projects around the site, including the manufacturing and testing of new

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prototype starships. For example, Ship
twenty six was recently spotted getting some work

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done at the test stand just to
the side of the orbital launch mount.

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We haven't really seen Ship twenty six
in a while, but this latest view

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has some folks confused. As you
can see, this prototype doesn't have flaps

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or even heat shield tiles, no
cargo bay doors or starlink dispensers either.

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Earlier sightings of Ship twenty six showed
these same things, of course, but

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back then it was too early to
tell if those features simply hadn't been added

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yet, and to be fair,
they still could be. But as Ship

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twenty six appears to be being prepped
to make a static fire test, it's

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far more likely that we are seeing
the very first test article for one of

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the most important systems in the SpaceX
ecosystem, the starship orbital fuel depot.

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The idea is to design a starship
that's just entirely a fuel tank, which

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the company will put into low Earth
orbit and keep topped up in case another

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starship might need more fuel for a
longer flight. SpaceX has plans for several

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variants of their starship, a crew
type, an uncrewed cargo type, a

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lander, even versions that can be
used to make space stations, and a

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fuel tanker variant would support all of
these, and while it might be too

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early to tell exactly what Ship twenty
six will be used for, its lack

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of fins or heat shield tiles as
it is preparing for static fire would seem

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to point to the fact that twenty
six is not intended to come back down

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to Earth. And more than that, SpaceX testing a potential fuel tanker version

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of their starship lines up with their
timeline for an orbital refueling demonstration that they

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are obligated to perform. It may
have gotten lost in the turmoil of testing

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and FAA investigations, but one of
the biggest reasons for the scramble to get

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a second test flight done for Starship
was that the company is on a tight

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schedule to get the vehicle up and
running in time to participate in the Artemis

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Moon missions, specifically Artemis three,
for which NASA has contracted the company's human

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Landing System Starship variant, due to
take place in twenty twenty five. The

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SpaceX HLS is due to carry a
crew of NASA astronauts to the surface of

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the lunar South Pole, but before
that can happen, NASA wants SpaceX to

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prove a few things. Obviously,
the first is that their starship can actually

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get into orbit, and in that
same thought that the Lander variant can you

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land. But the other critical test
for the Starship ecosystem is the in orbit

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refueling using a Starship fuel tanker,
and if Artemis three is to remain on

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schedule, that means that the testing
period for both the Lander and the fuel

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depot vehicles have to be completed in
twenty twenty four, and so it follows

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that we should be seeing prototypes for
those two vehicles about now if SpaceX plans

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to nail that timeline. Now,
looking over Ship twenty six, we can't

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see many exterior signs of new tech, but that doesn't mean much. If,

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for instance, Ship twenty six isn't
meant to test how Starship's fuel handles

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being in orbit for long periods of
time, then all it would need to

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have is a bunch of internal tanks
and some sensors. Some folks have also

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suggested that this ship could be used
to test maneuverability in orbit using its reaction

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control thrusters, which is definitely something
this variant could test without needing many conspicuous

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upgrades, But as it definitely doesn't
seem to have any sort of ship to

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ship dock and callers, it's not
likely to be testing the actual refueling functionality

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of a fuel depot. Seeing Ship
twenty six getting worked on while we wait

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for word of the next Starship launch
is encouraging. Like we said, SpaceX

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is also on a very tight schedule, and they can't afford to sit around

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even when government agencies slow things down
with investigations and environmental surveys, so it's

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a good thing the SpaceX team has
plenty to work on in the meantime.

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On September twelfth, NASA revealed an
expansion plan for the Kennedy Space Center in

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Florida, inviting the public to comment
on the new facilities. The document detailed

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several improvements for the busy spaceport,
not least of which was an over one

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hundred acre expansion of the SpaceX Roberts
Road facility near Pad thirty nine A,

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where the company launches most of their
Falcon Nines and is currently building their orbital

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launch apparatus for Starship. SpaceX currently
uses their roughly fifty acre plot at the

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Roberts Road site to maintain their fleet
of Falconine rockets that operate from Pad thirty

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nine A. This makes a good
deal of sense, as transporting even a

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tough rocket like the Falcon nine from
a further location would just be asking for

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delay causing mishaps. In a similar
manner, then it makes sense that SpaceX

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would want to eventually expand their facilities
on the Florida coast to at least accommodate

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the maintenance of an active fleet of
starships. Transporting the largest rocket ever built

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from Texas to Florida, even by
barge, seems like a pretty terrible idea,

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and obviously NASA agreed. The expansion
follows fairly closely to the original plan

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laid out in twenty twenty, which
was drawn up in phases, as these

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sorts of multi year construction projects often
are. Even back then, SpaceX was

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planning to at least grow its falconine
program and knew it would need more room

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eventually. Since then, however,
the company has gained a new starship flavored

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focus, and so the northern expansion
of the site will mostly be taken up

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by an enormous new hangar, which
is very likely to be a new starship

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maintenance and production facility. Not unlike
the star factory at Boca Chica, the

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plan looks fairly easy to complete.
Most of the literal groundwork was done in

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early twenty twenty one when the first
phase of the facility was constructed. Electrical,

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water and internet service is already there
and would just need to be routed

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a little further northwards, and the
supplemental environmental assessment NASA presented in their announcement

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seems to agree that the expansion isn't
a big issue either. The real problem

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is the gas line routing, which
is always a pain even in less industrial

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construction. But a much bigger deal
is a proposed expansion of the Saturn Causeway,

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an eight meter wide road that links
the historic vehicle assembly building to Pad

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thirty nine A, and which SpaceX
hope to use for transporting their Starship from

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the new facility to the pad.
The problem is that the starship is wider

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than the Saturn rockets were. In
fact, the Starship is nine meters in

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diameter, which would overhang the road. Their request is to widen the old

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causeway to ten point three meters to
accommodate Starship and its SPM transport vehicles.

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But in the grand scale of things, even these seemingly difficult engineering challenges are

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not much to worry about. Digging
gas lines and widening roads is fairly straightforward

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compared to wrangling an environmental survey.
But considering that part is already done,

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all SpaceX has to wait for here
is for the public comment period to close,

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and if by October sixteenth no major
issue is brought forward by residents nearby,

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NASA will make a final assessment and
SpaceX will be able to start planning

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their next big construction project. On
September twentieth, Hawaii played host to the

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fifth test of the inflatable Life module
made by Sierra Space, and the test

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article passed with flying colors. The
Large Integrated Flexible Environment is a mostly fabric

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habitation module designed to unfold during an
orbital flight by inflating. Sierra designed the

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three hundred and thirty cubic meter module
to be used on both the upcoming Blue

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Origin led Orbital Reef space station project
and with their Dream Chaser Crude shuttlecraft for

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longer duration missions. Most tests of
the design right now are being conducted on

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smaller subscale versions of the real thing, and are usually burst tests, which,

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as the name would suggest, involve
inflating the hab until it pops.

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This particular test added a metallic plate
meant to simulate a window, which will

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be built into the design in the
final version, But instead of weakening the

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design by breaking up the form of
the inflatable module as one might expect,

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the metal plate ended up lending some
extra strength, allowing the module to survive

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a full twenty percent more pressure than
previous tests and an overall thirty three percent

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margin of safety over the certification standard
for this sort of crude space. Obviously,

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this thrilled Sierra Spaces engineering staff,
who have been looking forward to clearing

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the series of gated tests so they
can get to a full in orbit demonstration.

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The testing for fabric based designs is
understandably stringent. There are a lot

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of benefits to inflatable modules, but
there just haven't been many real world tests

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of them to inspire more confidence.
The only inflatable hab to ever have been

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tested in space was the Bigelow Expandable
Activity Module or BEAM, constructed by Bigelow

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Aerospace and sent to the ISS back
in twenty sixteen and stayed there until twenty

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twenty. That test was successful and
showed some surprising advantages to inflatable modules.

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The first is somewhat obvious, because
it's inflatable, the module doesn't have to

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be aerodynamic and can simply be packed
into a rocket's fuselage until it's in space.

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The second is that most of these
modules are made from overlapping sheets of

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fabrics like kevlar, milar, and, in the case of Sierra's Life Module,

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a fabric called vectrin, which goes
rigid once inflated. This lends the

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module more protection against debris strikes than
even the more traditional hard shell aluminum designs,

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and finally, some designs even sport
better radiation protection, again depending on

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their construction. The issue, of
course, is that they are a new

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technology, and people get a little
nervous when you tell them that a bit

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of fabric is all that's protecting you
from the vacuum of space. So a

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series of tests is being conducted one
after another to thoroughly check the new Sierra

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Space module for any engineering shortfalls.
The team will take the next twenty four

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months to finish this testing gauntlet,
and then another twelve months after that to

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finish developing their flight hardware. It's
hard not to get swept up in the

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Sierra team's excitement. They have some
cool new tech and they know it.
