NASA astronaut Butch Wilmore (Expedition 42 commander on the International Space Station) holds the first 3-D printed part made in space, which was created on Nov. 25, 2014. Credit: NASA
Here’s the 22nd-century version of breaking the surly bonds of Earth: NASA and private company Made In Space have just collaborated on the first 3-D printed part in space, ever.
The milestone yesterday (Nov. 25) is a baby step towards off-Earth manufacturing, but the implications are huge. If these testbeds prove effective enough, eventually we can think of creating these parts in other destinations such as the Moon, or an asteroid, or even Mars.
“We look at the operation of the 3-D printer as a transformative moment, not just for space development, but for the capability of our species to live away from Earth,” stated Aaron Kemmer, CEO of Made In Space — the company that developed the printer.
There are still kinks to be worked out, however. The “part adhesion” on the tray after the piece was created had a bond that was mightier than controllers anticipated, which could mean that bonding is different in microgravity. A second calibration coupon should be created shortly as controllers make adjustments to the process.
Artist’s conception of a lunar dome based on 3-D printing. Credit: ESA/Foster + Partners
We’ll see several of these “test coupons” manufactured in the next few months and then sent back to Earth for more detailed analysis. Meanwhile, we have two more 3-D printers to look forward to in space: one created by the Italians that should arrive while their citizen, Samantha Cristoforetti, is still on station (she just arrived a few days ago) and a second one created by Made In Space that is supposed to commercialize the process.
The idea of 3-D printing has been discussed extensively in the media by both NASA and the European Space Agency in the past year or so. ESA has released media speculating on how additive manufacturing could be used to create Moon bases at some distant date. Meanwhile, NASA has talked about perhaps creating food using a 3-D printer.
If additive manufacturing takes off, so to speak, it could reduce shipping costs from Earth to the International Space Station because controllers could just send up a set of instructions to replace a part or tool. But NASA should move quickly to test this stuff out, according to a recent National Research Council report; the station is approved for operations only until 2020 (so far), which leaves only about five years or so to do testing before agencies possibly move to other destinations.
A Soyuz rocket carries the Expedition 42/3 crew to the International Space Station from Kazakhstan on Nov. 24, 2014. On board were Anton Shkaplerov (Roscosmos), Terry Virts (NASA) and Samantha Cristoforetti (European Space Agency). Credit: NASA/Aubrey Gemignani
And now we have six people in space again — including the first-ever Italian woman to reach orbit. Samantha Cristoforetti has been delighting people worldwide with her behind-the-scenes training posts as she prepares for her “Futura” mission, which will see her spend 5.5 months on the International Space Station with her crewmates. We have the NASA video from the big day above, and some photos from the launch below.
Cristoforetti has been sharing Spotify playlists and amusing tweets with more than 131,000 Twitter followers, not to mention people on Flickr and Google Plus. Her sense of humor and eye for the unusual will make for a fun few months in orbit along with the rest of her crew, NASA’s Terry Virts and Russia’s Anton Shkaplerov.
Just had what was probably my longest shower ever. Good Russian wisdom to leave plenty of time for it on the schedule! #NoRushOnLaunchDay
On station for their arrival last night was the second half of their crew: Barry Wilmore (NASA), Elena Serova (Russia) and Alexander Samoukutyaev (Russia). And in March 2015, a big event occurs: the first one-year mission on the International Space Station will begin with the arrival of the next crew.
The launch took place at 4:01 p.m. EDT (9:01 p.m. UTC) from the Baikonur Cosmodrome in Kazakhstan aboard a Soyuz rocket.
Prior to the launch of Expedition 42 in November 2014, Samantha Cristoforetti (left, European Space Agency) speaks with a loved one through the glass at a pre-launch press conference. Credit: NASA/Aubrey GemignaniPrior to the launch of Expedition 42 in November 2014, Anton Shkaplerov (Roscosmos, center) visits with a family member (at right) through the glass at a pre-flight press conference. In the background are his crewmates, from left: Terry Virts (NASA) Samantha Cristoforetti (ESA). Credit: NASA/Aubrey Gemignani
Antares descended into hellish inferno after first stage propulsion system at base of Orbital Sciences Antares rocket exploded moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014, at 6:22 p.m. Credit: Ken Kremer – kenkremer.com
Up close launch pad camera view as Antares descended into a hellish inferno after the first stage propulsion system at the base of Orbital Sciences’ Antares rocket exploded moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014, at 6:22 p.m. The south side engine nozzle is clearly intact in this image. Credit: Ken Kremer – kenkremer.com
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NASA WALLOPS FLIGHT FACILITY, VA – All was calm, the air was crisp with hope, and the skies were clear as far as the eye could see as the clock ticked down to T MINUS Zero for the Oct. 28, 2014, blastoff of an Orbital Sciences commercial Antares rocket from NASA’s Wallops Flight Facility, VA, on a mission of critical importance bound for the International Space Station and stocked with science and life support supplies for the six humans living and working aboard.
Tragically it was not to be – as I reported live from the NASA Wallops press site on that fateful October day. The 133 foot tall rocket’s base exploded violently and unexpectedly just seconds after a beautiful evening liftoff due to the failure of one of the refurbished AJ26 first stage “Americanized” Soviet-era engines built four decades ago.
And now for the first time, I can show you precisely what the terrible incendiary view was like through exclusive, up close launch pad photos and videos from myself and a group of space journalists working together from Universe Today, AmericaSpace, and Zero-G news.
Antares descended to doom after the first stage propulsion system at the base of Orbital Sciences’ Antares rocket exploded moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014, at 6:22 p.m. Credit: Ken Kremer – kenkremer.com
I was an eyewitness to the awful devastation suffered by the Antares/Cygnus Orb-3 mission from the press viewing site at NASA Wallops located at a distance of about 1.8 miles away from the launch complex.
Our remote cameras were placed directly adjacent to the Antares pad OA at the Mid-Atlantic Regional Spaceport (MARS) on Wallops Island, VA, and miraculously survived the rocket’s destruction as it plunged to the ground very near and just north of the seaside launch pad.
All of our team’s cameras and image cards were impounded by Orbital’s Accident Investigation Board (AIB) that was assembled quickly in the aftermath of the disaster and charged with determining the root cause of the launch failure.
The photos captured on our image cards were used as evidence and scrutinized by the investigators searching for clues as to the cause, and have only just been returned to us in the past two days. Similar NASA and Orbital Sciences photos have not been publicly released.
Collected here in Part 1 is a gallery of images from our combined journalist team of Universe Today, AmericaSpace, and Zero-G news. Part 2 will follow shortly and focus on our up close launch pad videos.
Close up view of Antares’ destruction shows the south side first stage engine intact after the north side engine at the base of Orbital Sciences’ rocket exploded moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014. Credit: Ken Kremer – kenkremer.comAntares descended into a hellish inferno after the first stage propulsion system at the base of Orbital Sciences’ Antares rocket exploded moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014, at 6:22 p.m. Credit: Ken Kremer – kenkremer.com
My lead image shows Antares’ descent into a hellish inferno. And more below clearly show that the south side engine nozzle was intact after the explosion. Thus it was the north side engine that blew up. See my up close AJ26 engine photo below.
Images from my colleagues Matthew Travis, Elliot Severn, Alex Polimeni, Charles Twine, and Jeff Seibert also show exquisite views of the explosion, fireball, and wreckage from various positions around the launch pad.
Antares destruction after the first stage propulsion system at the base of Orbital Sciences’ rocket exploded moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014. Credit: Ken Kremer – kenkremer.com
Close up view of Antares’ destructive fall shows the south side first stage engine intact after the north side engine at the base of Orbital Sciences’ rocket exploded moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014. Credit: Ken Kremer – kenkremer.com
Moments after liftoff, the highly anticipated Antares launch suddenly devolved into utter catastrophe and a doomed descent into a hellish inferno of bloodcurdling terror – falling as a flaming incinerating carcass of unspeakable horror that ended in a mammoth deafening explosion as the pitiful wreckage smashed into the ground and blew back upwards as a raging fireball and hurtling debris that was visible across a wide swath of the sky.
The awful scene was seen by hordes of expectant spectators for miles around the Wallops area.
The disaster’s cause has almost certainly been traced to a turbopump failure in one of the rocket’s Soviet-era first stage engines, according to official statements from David Thompson, Orbital’s Chairman and Chief Executive Officer.
The AJ26 engines were originally manufactured some 40 years ago in the then Soviet Union as the NK-33.
They were refurbished and “Americanized” by Aerojet Rocketdyne.
“While still preliminary and subject to change, current evidence strongly suggests that one of the two AJ26 main engines that powered Antares first stage failed about 15 seconds after ignition. At this time, we believe the failure likely originated in or directly affected the turbopump machinery of this engine, but I want to stress that more analysis will be required to confirm that this finding is correct,” said Thompson.
Overall this was the 5th Antares launch using the AJ26 engines.
The 14 story Antares rocket is a two stage vehicle.
The liquid fueled first stage is filled with about 550,000 pounds (250,000 kg) of Liquid Oxygen and Refined Petroleum (LOX/RP) and powered by a pair of AJ26 engines that generate a combined 734,000 pounds (3,265kN) of sea level thrust.
The Oct. 28 launch disaster was just the latest in a string of serious problems with the AJ-26/NK-33 engines.
Earlier this year an AJ26 engine failed and exploded during pre launch acceptance testing on a test stand on May 22, 2014 at NASA’s Stennis Space Center in Mississippi.
Besides completely destroying the AJ26 engine, the explosion during engine testing also severely damaged the Stennis test stand. It has taken months of hard work to rebuild and restore the test stand and place it back into service.
Antares was carrying Orbital’s privately developed Cygnus pressurized cargo freighter loaded with nearly 5000 pounds (2200 kg) of science experiments, research instruments, crew provisions, spare parts, spacewalk and computer equipment and gear on a critical resupply mission dubbed Orb-3 bound for the International Space Station (ISS).
It was the heaviest cargo load yet lofted by a Cygnus. Some 800 pounds additional cargo was loaded on board compared to earlier flights. That was enabled by using the more powerful ATK CASTOR 30XL engine to power the second stage for the first time.
The astronauts and cosmonauts depend on a regular supply train from the ISS partners to kept it afloat and productive on a 24/7 basis.
The Orbital-3, or Orb-3, mission was to be the third of eight cargo resupply missions to the ISS through 2016 under the NASA Commercial Resupply Services (CRS) contract award valued at $1.9 Billion.
Orbital Sciences is under contract to deliver 20,000 kilograms of research experiments, crew provisions, spare parts, and hardware for the eight ISS flights.
Enjoy the photo gallery herein.
And watch for Part 2 shortly with exquisite videos, more photos, and personal reflections from our team.
Antares descended into a hellish inferno after the first stage propulsion system at the base of Orbital Sciences’ Antares rocket exploded moments after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014, at 6:22 p.m. Credit: Ken Kremer – kenkremer.comAntares rocket stand erect, reflecting off the calm waters the night before the planned first night launch from NASA’s Wallops Flight Facility, VA, that ended in tragic failure on Oct. 28. Credit: Ken Kremer – kenkremer.com
Watch here for Ken’s ongoing reporting about Antares and NASA Wallops.
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Orbital Sciences Antares rocket explodes into an aerial fireball seconds after blastoff from NASA’s Wallops Flight Facility, VA, on Oct. 28, 2014 at 6:22 p.m. Credit: Ken Kremer – kenkremer.comSoviet era NK-33 engines refurbished as the AJ26 exactly like pictured here probably caused Antares’ rocket failure on Oct. 28, 2014. Orbital Sciences technicians at work on two AJ26 first stage engines at the base of an Antares rocket during exclusive visit by Ken Kremer/Universe Today at NASA Wallops. These engines powered the successful Antares liftoff on Jan. 9, 2014, at NASA Wallops, Virginia, bound for the ISS. Credit: Ken Kremer – kenkremer.comUp Close Launch Pad remote camera photographers during prelaunch setup for Orb-3 mission at NASA Wallops launch pad. Credit: Ken Kremer – kenkremer.com
The Columbus module is installed on the International Space Station in 2008. Pictured is NASA astronaut Rex Walheim. Credit: NASA
Need a part on the International Space Station? You’re going to have to wait for that. That is, wait for the next spaceship to arrive with the critical tool to make a repair, or replace something that broke. You can imagine how that slows down NASA’s desire for science on the orbiting laboratory.
Enter the first orbiting “machine shop”: a 3-D printer that was just installed in the station’s Columbus laboratory this week. If the printer works as planned, astronauts will be able to make simple things based on instructions from the ground. Over time, the agency hopes this will save time and money, and reduce the need to rely on shipments from Earth. And keep an eye out in 2015: two other 3-D printers are scheduled to join it.
As NASA aims to send astronauts to an asteroid and perhaps to Mars, the need to manufacture parts on site is critical. Sending a valve to Phobos isn’t an easy proposition. Much better that future crews will make stuff on the spot, and NASA says the space station will be a good spot to test this kind of stuff out. Adding motivation is a National Research Council report from this summer urging NASA to start 3-D printing testing as soon as possible, since the station (as of yet) is only funded by all partners through 2020. Negotiations are ongoing to extend that to 2024.
In November 2014, NASA astronaut Butch Wilmore installed a 3-D printer made by Made in Space in the Columbus laboratory’s Microgravity Science Glovebox on the International Space Station. Credit: NASA TV
“Additive manufacturing with 3-D printers will allow space crews to be less reliant on supply missions from Earth and lead to sustainable, self-reliant exploration missions where resupply is difficult and costly,” stated Jason Crusan, director of NASA’s advanced explorations systems division at NASA headquarters in Washington. “The space station provides the optimal place to perfect this technology in microgravity.”
But don’t get too excited yet; astronauts aren’t going to make screwdrivers right away. The first step will be calibrating the printer. Then, the first files (mainly test coupons) will be printed and sent back to Earth to make sure they meet up to standards compared to identical samples printed on the ground with the same printer.
Made In Space Inc. manufactured this printer (which arrived on station in September) with the aim of sending up a more advanced version in 2015. In a statement, the company said it is “gratified” that the printer is ready to go in space. Any science collected on it will inform the design of the new printer, “which will enable a fast and cost-effective way for people to get hardware to space,” the company added.
And guess what: there is yet another printer that will be launched to the space station next year. Called the POP3D Portable On-Board Printer, the European Space Agency promises that the tiny machine — less than half the diameter of a basketball — will be able to print a plastic part in about half an hour.
The prime contractor for this printer is Italian company Altran. POP3D will reach the station in the first half of next year, ideally while Italy’s Samantha Cristoforetti is still doing her Futura mission in space (which starts this Sunday, if the launch schedule holds.)
ISS-RapidScat data on a North Atlantic extratropical cyclone, as seen by the National Centers for Environmental Prediction Advanced Weather Interactive Processing System used by weather forecasters at the National Oceanic and Atmospheric Administration's Ocean Prediction Center.
Image Credit:
NASA/JPL-Caltech/NOAA
Barely two months after being launched to the International Space Station (ISS), NASA’s first science payload aimed at conducting Earth science from the station’s exterior has started its ocean wind monitoring operations two months ahead of schedule.
Data from the ISS Rapid Scatterometer, or ISS-RapidScat, payload is now available to the world’s weather and marine forecasting agencies following the successful completion of check out and calibration activities by the mission team.
Indeed it was already producing high quality, usable data following its power-on and activation at the station in late September and has monitored recent tropical cyclones in the Atlantic and Pacific Oceans prior to the end of the current hurricane season.
RapidScat is designed to monitor ocean winds for climate research, weather predictions, and hurricane monitoring for a minimum mission duration of two years.
“RapidScat is a short mission by NASA standards,” said RapidScat Project Scientist Ernesto Rodriguez of JPL.
“Its data will be ready to help support U.S. weather forecasting needs during the tail end of the 2014 hurricane season. The dissemination of these data to the international operational weather and marine forecasting communities ensures that RapidScat’s benefits will be felt throughout the world.”
ISS-RapidScat instrument, shown in this artist’s rendering, was launched to the International Space Station aboard the SpaceX CRS-4 mission on Sept. 21, 2014, and attached at ESA’s Columbus module. It will measure ocean surface wind speed and direction and help improve weather forecasts, including hurricane monitoring. Credit: NASA/JPL-Caltech/Johnson Space Center.
The 1280 pound (580kilogram) experimental instrument was developed by NASA’s Jet Propulsion Laboratory. It’s a cost-effective replacement to NASA’s former QuikScat satellite.
The $26 million remote sensing instrument uses radar pulses reflected from the ocean’s surface at different angles to calculate the speed and direction of winds over the ocean for the improvement of weather and marine forecasting and hurricane monitoring.
The RapidScat, payload was hauled up to the station as part of the science cargo launched aboard the commercial SpaceX Dragon CRS-4 cargo resupply mission that thundered to space on the company’s Falcon 9 rocket from Space Launch Complex-40 at Cape Canaveral Air Force Station in Florida on Sept. 21.
ISS-RapidScat is NASA’s first research payload aimed at conducting near global Earth science from the station’s exterior and will be augmented with others in coming years.
ISS-RapidScat viewed the winds within post-tropical cyclone Nuri as it moved parallel to Japan on Nov. 6, 2014, 05:30 UTC. Image Credit: NASA/JPL-Caltech
It was robotically assembled and attached to the exterior of the station’s Columbus module using the station’s robotic arm and DEXTRE manipulator over a two day period on Sept 29 and 30.
Ground controllers at Johnson Space Center intricately maneuvered DEXTRE to pluck RapidScat and its nadir adapter from the unpressurized trunk section of the Dragon cargo ship and attached it to a vacant external mounting platform on the Columbus module holding mechanical and electrical connections.
The nadir adapter orients the instrument to point its antennae at Earth.
The couch sized instrument and adapter together measure about 49 x 46 x 83 inches (124 x 117 x 211 centimeters).
“The initial quality of the RapidScat wind data and the timely availability of products so soon after launch are remarkable,” said Paul Chang, ocean vector winds science team lead at NOAA’s National Environmental Satellite, Data and Information Service (NESDIS)/Center for Satellite Applications and Research (STAR), Silver Spring, Maryland.
“NOAA is looking forward to using RapidScat data to help support marine wind and wave forecasting and warning, and to exploring the unique sampling of the ocean wind fields provided by the space station’s orbit.”
A SpaceX Falcon 9 rocket carrying a Dragon cargo capsule packed with science experiments and station supplies blasts off from Space Launch Complex 40 at Cape Canaveral Air Force Station, Florida, at 1:52 a.m. EDT on Sept. 21, 2014, bound for the ISS. Credit: Ken Kremer/kenkremer.com
This has been a banner year for NASA’s Earth science missions. At least five missions will be launched to space within a 12 month period, the most new Earth-observing mission launches in one year in more than a decade.
ISS-RapidScat is the third of five NASA Earth science missions scheduled to launch over a year.
NASA has already launched the of the Global Precipitation Measurement (GPM) Core Observatory, a joint mission with the Japan Aerospace Exploration Agency, in February and the Orbiting Carbon Observatory-2 (OCO-2) carbon observatory in July 2014.
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Doesn’t this make you want to book a trip on the next spaceship? Stunning footage from space here shows what auroras look like from the International Space Station. So many ripples of green. Such awesomeness.
Tracks in the snow mark Expedition 41's landing from the space station Nov. 9, 2014. Credit: NASA/Bill Ingalls
Check out that landing mark! A Soyuz spacecraft carrying three people touched down safely in remote Kazakhstan late Sunday (EDT) and went for a brief sleigh ride in the snow, as you can see from the drag marks on the landscape.
The flawless landing included the Expedition 40/41 crew members of Reid Wiseman (NASA), Alexander Gerst (European Space Agency) and Maxim Suraev (Roscosmos), who spent 165 days in space, mainly living on the International Space Station. Check out some more landing pictures and video below.
Alexander Gerst, an astronaut from the European Space Agency, does a fist pump shortly after the safe Expedition 41 landing Nov. 9, 2014. Credit: ESA–S. Corvaja, 2014
My favorite part of the video is the Cygnus release. What's yours?
Yes, it’s another time-lapse video made from photos taken by astronauts aboard the ISS. Yes, it’s been digitally remastered, smoothed-over, and set to a dramatic technopop soundtrack. But no, it’s still not boring because our planet is beautiful and spaceflight is and always will be absolutely fascinating.
There. I said it.
The video above “Astronaut – a Journey to Space” is everything that I just mentioned and was compiled and edited by photographer and video artist Guillaume Juin. The original images were gathered from Johnson Space Center’s Gateway to Astronaut Photography of Earth site, and were captured during ISS missions from 2011 to 2014. Aforementioned dramatic technopop music is by Vincent Tone. Watch it above, or for maximum impact watch it full-screen. (I strongly advise the latter.) Enjoy!
HT to Sploid and fellow EFT-1 NASA Social participant Ailyn Marie for bringing this to my attention.
Expedition 40 astronauts Reid Wiseman (left) and Alexander Gerst as viewed in a water bubble surrounding a video camera on the International Space Station. Credit: NASA/YouTube (screenshot)
What does the view look like from inside a water bubble? Earlier this year, astronauts on the International Space Station completely submersed a GoPro video recorder inside liquid and filmed the view — which is quite amusing.
Look below for some distorted views of then-Expedition 40 astronauts Reid Wiseman and Alexander Gerst … and an awesome 3-D video besides!
NASA’s goal in tasking the astronauts with this is to better understand how water behaves in space. (It’s actually quite a serious matter, as a lack of understanding of the physics was one factor leading to a dangerous water leak during a spacewalk in 2013.) In this case, the astronauts were looking at how surface tension works in microgravity.
As for that 3-D video, the agency says it is going to offer more of these from space as it gets people even closer to actually being there. Here’s a neat phenomenon: typically the higher radiation levels in space damage video cameras to the extent where they need to be replaced every 8-12 months.
A 3-D camera sent up in 2011, however, had virtually no dead pixels in the images, prompting NASA to investigate. Officials requested the camera come back to Earth on a Dragon splashdown in 2012. That’s when they discovered the way the 3-D camera is structured — with stereo images layered on top of each other — lessens the appearance of any damage.
But there’s also less damage in the first place, NASA said, because the 3-D camera doesn’t use charge-coupled imaging sensors that are susceptible to radiation. The newer system uses a metal-oxide semiconductor sensor, which doesn’t get hurt as badly. We guess that’s more argument for bringing 3-D images from the final frontier.
Expedition 40 commander Steve Swanson (left) and Reid Wiseman view a water bubble surrounding a video camera on the International Space Station in summer 2014. Credit: NASA/YouTube (screenshot)
The International Space Station as seen by the departing STS-134 crew on May 29, 2011. Credit: NASA
A spacecraft attached to the International Space Station did an “emergency maneuver” to push the complex, which now houses six people, away from a threatening piece of space debris Oct. 27, the European Space Agency said in a statement.
A hand-sized shard of the Russian Cosmos-2251 satellite, which collided with a U.S. Iridium satellite in 2009, would have come within at least four kilometers (2.5 miles) of the orbiting outpost. This was close enough for the space station partners to agree to a move six hours before the potential impact.
“This is the first time the station’s international partners have avoided space debris with such urgency,” the European Space Agency wrote. The push to a safer orbit took place using the agency’s automated transfer vehicle Georges Lemaître, which docked with the space station in August.
The International Space Station in October 2014, with the European automated transfer vehicle Georges Lemaître attached. Credit: Alexander Gerst/ESA/NASA
While many collision threats are spotted at least days before impact, occasionally ground networks aren’t able to see a piece until 24 hours or less before the potential impact. Since 2012, the space station has normally done last-minute maneuvers using Russian cargo Progress vehicles, but this time around none were docked there. This is where the ATV came in.
Controllers at the ATV control center in France then did a four-minute preprogrammed move that raised the station’s orbit by one kilometer (0.6 miles), enough to get out of the way.
The ATV is expected to remain at the station until February, when it will undock and burn up in the atmosphere. This is the last of the series of ATVs that Europe agreed to make as a part of its space station agreement.
