Building the World’s First Commercial Space Station

When most people think of living and working in space, they're likely envisioning the International Space Station (ISS), a world-class, state of the art laboratory in low-Earth orbit (LEO) that has been operated by a collaboration of 15 nations for more than 25 years.

As work aboard the aging ISS winds down over the next decade, the future of space habitation will revolve around the first commercial space station, which will look quite different and be founded on technology from Sierra Space. The next generation of astronauts that will embark on extended missions in space will likely do so via an inflatable soft goods platform comprised of interwoven fabrics that are packed on launch and expanded once deployed in orbit.

We see unlimited potential in this technology, and our company is leading the charge towards a science and biopharma platform designed to allow humans to live and work comfortably in LEO and beyond. Specifically, we're perfecting LIFE®: an orbital space station business platform designed not just for LEO, but also for future missions on the moon's surface and to deep space.

This inflatable space station technology is revolutionary and will change the way we interact with near and distant space. In this article, we'll answer some of the leading questions on this groundbreaking innovation.

About LIFE

Our LIFE (Large Integrated Flexible Environment) technology launches on a conventional rocket. Its inflatable structure remains tightly packed upon deployment. One of the first in our product line, LIFE285, will inflate into a structure that is three stories tall and 27 feet in diameter once it reaches space-essentially the size of a three-story apartment, with each floor being nine feet tall.

The inflatable structural shell is made up of a tightly woven fabric (Vectran) that's up to five times stronger than steel once inflated, and offers a balance of properties unmatched by other high-performance fibers. This strong structural shell, as well as its spacious interior, makes it perfect for both LEO and long-duration missions to the moon, Mars and the stars.

Why an inflatable softgoods shell? The problem with large, metallic space stations is that they're hard (and expensive) to launch into space. That's where the magic of an inflatable spacecraft comes into play. Launched in a packed state, it can easily reach space and expand to huge volumes.

Once fully inflated, the interior of LIFE285 will be able to accommodate anywhere from four to twelve people, depending on the purpose and length of the mission.

It can also fully packed with essential amenities, including an Astro Garden® for a constant supply of fresh produce, ample sleeping quarters, a medic chamber, and exercise equipment. Thus, it serves as the ultimate home-away-from-home for longer duration space missions.

The Current LIFE Ground Prototype

Just like any other crewed mission to space, there are strict safety guidelines in place by NASA that companies must follow before deployment. To address this, we've developed a full-scale prototype of LIFE285 to assess its safety and efficacy.

Although this prototype won't be going to space, it will be invaluable in helping our engineers optimize the best approach to transferring the LIFE technology into in orbit operations.

Any space habitation must account for practicalities such as the crew's equipment. LIFE will house many scientists and engineers, so the necessary tools and instruments must be incorporated. That means fully functional science labs and spacious workstations.

Another consideration is proper air circulation. Air will have to be constantly filtered and mixed with fresh oxygen to maintain breathable conditions while preventing stagnant air pockets. What's more, there needs to be close environmental monitoring for air quality, temperature, humidity, and radiation levels.

Finally, long trips require adequate lighting and food solutions. Our prototypes will test the longevity and energy savings of LED lighting. Additionally, Sierra Space's Astro Garden system is poised to be an abundant source of food for and mental wellbeing for future astronauts.

LIFE's Testing Status

Our LIFE technology is decades in the making. Backed by a talented and driven team of engineers and scientists, our goal is to reach structural perfection in the near future.

We have gone through numerous stress tests to make this a reality.

A stress test assesses the structure's resilience under the most extreme conditions. Previous tests, such as the Ultimate Burst Pressure (UBP) test, dealt with the maximum pressure that the inflatable craft could contain-all of which were overwhelmingly successful.

During a UBP test, the teams inflate the test article until it fails, which helps determine how strong its softgoods materials would be under extreme stresses in the harsh environment of space.

Our team achieved a groundbreaking UBP milestone in December by successfully designing, manufacturing, assembling, and testing our first full-scale LIFE285, expandable space station structure. The test unit stood over 20' tall and was 1/3 the volume of the International Space Station. Test results exceeded NASA's recommended x4 safety levels by 27%.

We also conducted Accelerated Systematic sub scale (LIFE10) creep tests, which determined the maximum time that the softgoods structure could withstand high pressure to calculate overall life expectancy in years. Sierra Space's and NASA's suggested guideline targets were short and medium duration tests based on 100 and 1,000 hours, and our softgoods shell lasted well over 150 hours on the short duration and met the medium duration performance expectations, marking a huge step in the future of human space habitation.

Our team is continuing to push the boundaries of the softgoods inflatable habitat technology by leveraging advancements in LIFE10 (10 cubic meters) LIFE285 (285 cubic meters) and now introducing LIFE500 (500 cubic meters). We will continue to conduct test campaigns in 2024 and early 2025 by testing two LIFE10, two LIFE285, and one LIFE500.

The Future of LIFE

The inflatable technology used on LIFE will revolutionize the future of commercial space and microgravity research. Its flexibility opens the door for several different kinds of space missions.

Our researchers are working to support deep space exploration to Mars. With abundant food, comfortable living quarters, and state-of-the-art durability, LIFE is the ideal craft for long-duration missions.

This would be a significant advancement in space exploration, showcasing our ability to sustain human life on an interplanetary scale-something that is yet to be seen in our current space endeavors.

An inflatable commercial space station can also make longer missions to the moon possible and more accessible. These efforts can increase our capacity to survive on other planets, leading to an array of new and exciting possibilities.

Learn More About Sierra Space's Innovations

Society is increasingly looking toward the skies for answers and opportunities. Recent inflatable spacecraft technologies have shown that space exploration is possible, and our company is proud to be a leader in this evolutionary movement.

With advanced durability and volume, commercial space stations like the LIFE product line will be pivotal in manned missions to the moon and Mars. Keep a close eye on the news: big things are coming in the near future.

We are at the forefront of commercial spacecraft innovation. We focus on advanced solutions, from optimized trash handling to the future of inflatable space stations. Ultimately, our aim is to make human presence in space more accessible and sustainable.

If you're interested in the technology and innovation involved with space exploration, learn more about our company and mission today.

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