Louisville, Colorado - The first Dream Chaser spaceplane designed for orbital missions is now taking on its definitive form. Its foldable wings and fuselage are equipped with specially tailored ceramic tiles, providing protection to the spacecraft's composite structure during the intense heat of atmospheric reentry as it returns to Earth. The craft boasts its landing gear, and technicians are diligently applying the finishing touches before it departs the manufacturing facility.

Inside the spacecraft, workers are in the process of installing the final ducts for the environmental control system, ensuring a habitable environment for astronauts at the International Space Station within the Dream Chaser's pressurized compartment. Presently, the primary role of the Dream Chaser is to transport cargo to and from the research complex orbiting approximately 240 miles (385 kilometers) above Earth. It will be launched atop a conventional rocket, maneuver in space akin to a satellite, and then execute a runway landing.

Adjacent to the production area, Sierra Space has established a mission control room, where engineers will oversee and command the spacecraft during its orbital missions. Further down the corridor, a mock-up is in place to facilitate astronaut training on how to embark and disembark from the Dream Chaser and manage cargo operations while docked at the station.

This recent scene unfolded as Ars visited Sierra Space in Louisville, Colorado, a suburb situated northwest of Denver. During the visit, several hundred employees paused briefly to hear words of commendation from Sierra Space leadership. Within the coming weeks, the Dream Chaser spaceplane, named "Tenacity" and bearing the serial number DC-101, will embark on its journey to a NASA facility in Ohio for an extensive battery of tests aimed at confirming its capability to endure the demands of spaceflight.

Dream Chaser Nearing Completion for Next Round of Tests

Some components, including covers and tiles, are still pending installation on the spacecraft. Tom Vice, the CEO of Sierra Space and a former executive at Northrop Grumman, explained that engineers intentionally left certain components off the Dream Chaser for its upcoming round of tests.

"We're almost done with everything," noted Angie Wise, Sierra Space's chief safety officer. "We're finishing all the closeout panels, essentially preparing it for shipping. We've checked out the landing gear. We're going to reinstall everything, stow it, and then move it onto the transport fixture for removal from the facility."

The Dream Chaser spacecraft represents a remarkable and innovative vision for the future of spaceflight, merging elements of both rockets and aircraft. NASA has maintained a continuous interest in spaceplanes since its inception, and the military has also been a proponent of spaceplanes for nearly six decades. Virgin Galactic operates a suborbital spaceplane for space tourism and research missions.

In the realm of spaceplanes, Sierra Space isn't the only player. However, the company stands out due to its unwavering commitment in an industry that has recently favored capsule-shaped spacecraft or unconventional designs, such as SpaceX's reusable Starship rocket. Dream Chaser is set to become the first commercial spaceplane capable of orbital flight.

Tom Vice expressed, "We are introducing the world's first revolutionary space line. This will change how we travel from Earth to space and back again." Sierra Space has emphasized that its Dream Chaser will ensure a gentle return to Earth for cargo, subjecting it to no more than 1.5 Gs of force. This feature is particularly valuable for transporting delicate items like animal specimens and other sensitive payloads. Furthermore, Dream Chaser's capability extends to delivering payloads in proximity to the research laboratories responsible for analyzing experiment outcomes. Tom Vice remarked, "Descents into the ocean can be quite harsh, but landing on a runway offers a significantly more favorable experience."