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Dream Chaser Tenacity (DC101) is the first Dream Chaser spacecraft expected to fly in space. Manufactured by the Sierra Nevada Corporation, it will first fly to the International Space Station as part of the SNC Demo-1 mission in 2025, under the CRS-2 contract.

The Sierra Nevada Corporation was awarded a CRS-2 contract for by NASA for six operational resupply spaceflights to the International Space Station. SNC Demo-1 is a demo flight that will precede the operational resupply flights if the mission is successful.

Tenacity and other Dream Chasers will be mated with a Shooting Star module, which will provide an additional 10,000 lb (4,500 kg) of payload capacity, in addition to the 2,000 lb (910 kg) carried by the space plane. The module will be separated from the Dream Chaser prior to reentry and burn up in the atmosphere, while the Dream Chaser vehicle will perform a runway landing to be reused.

Dream Chaser is an American reusable lifting-body space plane developed by Sierra Space. Originally intended as a crewed vehicle, the Dream Chaser Space System is set to be produced after the Dream Chaser Cargo System cargo variant is operational. The crewed variant is planned to carry up to seven people and cargo to and from low Earth orbit. Sierra plans to manufacture a fleet of the space plane.

The Dream Chaser was originally started in 2004 as a project of SpaceDev, a company that was later acquired by the Sierra Nevada Corporation (SNC) in 2008. In April 2021 the project was taken over by the Sierra Space Corporation (SSC), which at that time was spun off from the Sierra Nevada Corporation as its own fully independent company.

The cargo Dream Chaser is designed to resupply the International Space Station with both pressurized and unpressurized cargo. It is intended to be launched vertically on the Vulcan Centaur rocket and autonomously land horizontally on conventional runways. A proposed version to be operated by European Space Agency (ESA) would launch on an Arianespace vehicle.

The Dream Chaser space plane is designed to be launched on the top of a typical rocket and land like an airplane on a runway. The design has heritage going back decades. Currently, the Dream Chaser will resupply the ISS with cargo.

On-orbit propulsion of the Dream Chaser was originally proposed to be provided by twin hybrid rocket engines capable of repeated starts and throttling. At the time, the SSC’s predecessor, the SNC was also developing a similar hybrid rocket for Virgin Galactic’s SpaceShipTwo. In May 2014, SNC involvement in the SpaceShipTwo program ended.

After the acquisition of Orbitec LLC in July 2014, Sierra Nevada Corporation announced a major change to the propulsion system. The hybrid rocket engine design was dropped in favor of a cluster of Orbitec’s Vortex engines. The new unit would be a pressure-fed three-mode engine. At low- and mid-power regimes it uses monopropellant fuel – hydrogen peroxide – and in high-power demand, the engine adds injection of RP-1 fuel. This increased thrust will be useful to shorten the de-orbit burn duration of the Dream Chaser.

Its thermal protection system (TPS) is made up of silica-based tiles (for most of the belly and upper portion of the heat shield), and a new composite material called Toughened Unipiece Fibrous Reusable Oxidation Resistant Ceramic (TUFROC) to cover the nose and leading edges.

In 2019, it was announced that an expendable Shooting Star cargo module would be part of the Dream Chaser cargo system for CRS-2 flights. The module is a 15-foot-long (4.6 m) attachment to Dream Chaser that will allow the spacecraft to carry an additional 10,000 pounds (4,500 kg) of pressurized and unpressurized cargo to ISS. The module supports disposal of unwanted cargo by burning up upon re-entry.

In addition to carrying cargo, the Shooting Star module includes solar panels that supply up to 6 kW of electrical power. It also supplies active and passive thermal management; provides Dream Chaser translation and rotation capability via six mounted thrusters; and supports berthing or docking (in different configurations) to the ISS. Access from ISS to Dream Chaser will involve crew passing through Shooting Star (which supports a shirt-sleeve environment) and through a hatch that separates Shooting Star from Dream Chaser. Sierra Nevada says the module is capable of additional types of missions in LEO or to cis-lunar destinations; they have developed a free-flying variant with additional capabilities.

Video credit: Sierra Space