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NASA Marshall Fires Up Hybrid Rocket Motor to Prep for Moon Landings

24 April 2025 at 16:20
4 Min Read

NASA Marshall Fires Up Hybrid Rocket Motor to Prep for Moon Landings

NASA’s Artemis campaign will use human landing systems, provided by SpaceX and Blue Origin, to safely transport crew to and from the surface of the Moon, in preparation for future crewed missions to Mars. As the landers touch down and lift off from the Moon, rocket exhaust plumes will affect the top layer of lunar “soil,” called regolith, on the Moon. When the lander’s engines ignite to decelerate prior to touchdown, they could create craters and instability in the area under the lander and send regolith particles flying at high speeds in various directions.

To better understand the physics behind the interaction of exhaust from the commercial human landing systems and the Moon’s surface, engineers and scientists at NASA’s Marshall Space Flight Center in Huntsville, Alabama, recently test-fired a 14-inch hybrid rocket motor more than 30 times. The 3D-printed hybrid rocket motor, developed at Utah State University in Logan, Utah, ignites both solid fuel and a stream of gaseous oxygen to create a powerful stream of rocket exhaust.

“Artemis builds on what we learned from the Apollo missions to the Moon. NASA still has more to learn more about how the regolith and surface will be affected when a spacecraft much larger than the Apollo lunar excursion module lands, whether it’s on the Moon for Artemis or Mars for future missions,” said Manish Mehta, Human Landing System Plume & Aero Environments discipline lead engineer. “Firing a hybrid rocket motor into a simulated lunar regolith field in a vacuum chamber hasn’t been achieved in decades. NASA will be able to take the data from the test and scale it up to correspond to flight conditions to help us better understand the physics, and anchor our data models, and ultimately make landing on the Moon safer for Artemis astronauts.”

Fast Facts

  • Over billions of years, asteroid and micrometeoroid impacts have ground up the surface of the Moon into fragments ranging from huge boulders to powder, called regolith.
  • Regolith can be made of different minerals based on its location on the Moon. The varying mineral compositions mean regolith in certain locations could be denser and better able to support structures like landers.

Of the 30 test fires performed in NASA Marshall’s Component Development Area, 28 were conducted under vacuum conditions and two were conducted under ambient pressure. The testing at Marshall ensures the motor will reliably ignite during plume-surface interaction testing in the 60-ft. vacuum sphere at NASA’s Langley Research Center in Hampton, Virginia, later this year.

Once the testing at NASA Marshall is complete, the motor will be shipped to NASA Langley. Test teams at NASA Langley will fire the hybrid motor again but this time into simulated lunar regolith, called Black Point-1, in the 60-foot vacuum sphere. Firing the motor from various heights, engineers will measure the size and shape of craters the rocket exhaust creates as well as the speed and direction the simulated lunar regolith particles travel when the rocket motor exhaust hits them.

“We’re bringing back the capability to characterize the effects of rocket engines interacting with the lunar surface through ground testing in a large vacuum chamber — last done in this facility for the Apollo and Viking programs. The landers going to the Moon through Artemis are much larger and more powerful, so we need new data to understand the complex physics of landing and ascent,” said Ashley Korzun, principal investigator for the plume-surface interaction tests at NASA Langley. “We’ll use the hybrid motor in the second phase of testing to capture data with conditions closely simulating those from a real rocket engine. Our research will reduce risk to the crew, lander, payloads, and surface assets.”

Credit: NASA

Through the Artemis campaign, NASA will send astronauts to explore the Moon for scientific discovery, economic benefits, and to build the foundation for the first crewed missions to Mars – for the benefit of all.

For more information about Artemis, visit:

https://www.nasa.gov/artemis

News Media Contact

Corinne Beckinger 
Marshall Space Flight Center, Huntsville, Ala. 
256.544.0034  
corinne.m.beckinger@nasa.gov 

NASA Marshall Fires Up Hybrid Rocket Motor to Prep for Moon Landings

24 April 2025 at 16:20
4 Min Read

NASA Marshall Fires Up Hybrid Rocket Motor to Prep for Moon Landings

NASA’s Artemis campaign will use human landing systems, provided by SpaceX and Blue Origin, to safely transport crew to and from the surface of the Moon, in preparation for future crewed missions to Mars. As the landers touch down and lift off from the Moon, rocket exhaust plumes will affect the top layer of lunar “soil,” called regolith, on the Moon. When the lander’s engines ignite to decelerate prior to touchdown, they could create craters and instability in the area under the lander and send regolith particles flying at high speeds in various directions.

To better understand the physics behind the interaction of exhaust from the commercial human landing systems and the Moon’s surface, engineers and scientists at NASA’s Marshall Space Flight Center in Huntsville, Alabama, recently test-fired a 14-inch hybrid rocket motor more than 30 times. The 3D-printed hybrid rocket motor, developed at Utah State University in Logan, Utah, ignites both solid fuel and a stream of gaseous oxygen to create a powerful stream of rocket exhaust.

“Artemis builds on what we learned from the Apollo missions to the Moon. NASA still has more to learn more about how the regolith and surface will be affected when a spacecraft much larger than the Apollo lunar excursion module lands, whether it’s on the Moon for Artemis or Mars for future missions,” said Manish Mehta, Human Landing System Plume & Aero Environments discipline lead engineer. “Firing a hybrid rocket motor into a simulated lunar regolith field in a vacuum chamber hasn’t been achieved in decades. NASA will be able to take the data from the test and scale it up to correspond to flight conditions to help us better understand the physics, and anchor our data models, and ultimately make landing on the Moon safer for Artemis astronauts.”

Fast Facts

  • Over billions of years, asteroid and micrometeoroid impacts have ground up the surface of the Moon into fragments ranging from huge boulders to powder, called regolith.
  • Regolith can be made of different minerals based on its location on the Moon. The varying mineral compositions mean regolith in certain locations could be denser and better able to support structures like landers.

Of the 30 test fires performed in NASA Marshall’s Component Development Area, 28 were conducted under vacuum conditions and two were conducted under ambient pressure. The testing at Marshall ensures the motor will reliably ignite during plume-surface interaction testing in the 60-ft. vacuum sphere at NASA’s Langley Research Center in Hampton, Virginia, later this year.

Once the testing at NASA Marshall is complete, the motor will be shipped to NASA Langley. Test teams at NASA Langley will fire the hybrid motor again but this time into simulated lunar regolith, called Black Point-1, in the 60-foot vacuum sphere. Firing the motor from various heights, engineers will measure the size and shape of craters the rocket exhaust creates as well as the speed and direction the simulated lunar regolith particles travel when the rocket motor exhaust hits them.

“We’re bringing back the capability to characterize the effects of rocket engines interacting with the lunar surface through ground testing in a large vacuum chamber — last done in this facility for the Apollo and Viking programs. The landers going to the Moon through Artemis are much larger and more powerful, so we need new data to understand the complex physics of landing and ascent,” said Ashley Korzun, principal investigator for the plume-surface interaction tests at NASA Langley. “We’ll use the hybrid motor in the second phase of testing to capture data with conditions closely simulating those from a real rocket engine. Our research will reduce risk to the crew, lander, payloads, and surface assets.”

Credit: NASA

Through the Artemis campaign, NASA will send astronauts to explore the Moon for scientific discovery, economic benefits, and to build the foundation for the first crewed missions to Mars – for the benefit of all.

For more information about Artemis, visit:

https://www.nasa.gov/artemis

News Media Contact

Corinne Beckinger 
Marshall Space Flight Center, Huntsville, Ala. 
256.544.0034  
corinne.m.beckinger@nasa.gov 

NASA Selects Finalist Teams for Student Human Lander Challenge

4 April 2025 at 12:00
Human Lander Challenge (HuLC) banner.

NASA has selected 12 student teams to develop solutions for storing and transferring the super-cold liquid propellants needed for future long-term exploration beyond Earth orbit.

The agency’s 2025 Human Lander Challenge is designed to inspire and engage the next generation of engineers and scientists as NASA and its partners prepare to send astronauts to the Moon through the Artemis campaign in preparation for future missions to Mars. The commercial human landing systems will serve as the primary mode of transportation that will safely take astronauts and, later, large cargo from lunar orbit to the surface of the Moon and back.

For its second year, the competition invites university students and their faculty advisors to develop innovative, “cooler” solutions for in-space cryogenic, or super cold, liquid propellant storage and transfer systems. These cryogenic fluids, like liquid hydrogen or liquid oxygen, must stay extremely cold to remain in a liquid state, and the ability to effectively store and transfer them in space will be increasingly vital for future long-duration missions. Current technology allows cryogenic liquids to be stored for a relatively short amount of time, but future missions will require these systems to function effectively over several hours, weeks, and even months.

The 12 selected finalists have been awarded a $9,250 development stipend to further develop their concepts in preparation for the next stage of the competition.

The 2025 Human Lander Challenge finalist teams are:

  • California State Polytechnic University, Pomona, “THERMOSPRING: Thermal Exchange Reduction Mechanism using Optimized SPRING”
  • Colorado School of Mines, “MAST: Modular Adaptive Support Technology”
  • Embry-Riddle Aeronautical University, “Electrical Capacitance to High-resolution Observation (ECHO)”
  • Jacksonville University, “Cryogenic Complex: Cryogenic Tanks and Storage Systems – on the Moon and Cislunar Orbit”
  • Jacksonville University, “Cryogenic Fuel Storage and Transfer: The Human Interface – Monitoring and Mitigating Risks”
  • Massachusetts Institute of Technology, “THERMOS: Translunar Heat Rejection and Mixing for Orbital Sustainability”
  • Old Dominion University, “Structural Tensegrity for Optimized Retention in Microgravity (STORM)”
  • Texas A&M University, “Next-generation Cryogenic Transfer and Autonomous Refueling (NeCTAR)”
  • The College of New Jersey, “Cryogenic Orbital Siphoning System (CROSS)”
  • The Ohio State University, “Autonomous Magnetized Cryo-Couplers with Active Alignment Control for Propellant Transfer (AMCC-AAC)
  • University of Illinois, Urbana-Champaign, “Efficient Cryogenic Low Invasive Propellant Supply Exchange (ECLIPSE)”
  • Washington State University, “CYPRESS (CrYogenic Performance REfueling Safety System) Coupler for Liquid Hydrogen Transfer”

Finalist teams will now work to submit a technical paper further detailing their concepts. They will present their work to a panel of NASA and industry judges at the 2025 Human Lander Competition Forum in Huntsville, Alabama, near NASA’s Marshall Space Flight Center, in June 2025. The top three placing teams will share a total prize purse of $18,000.

“By engaging college students in solving critical challenges in cryogenic fluid technologies and systems-level solutions, NASA fosters a collaborative environment where academic research meets practical application,” said Tiffany Russell Lockett, office manager for the Human Landing System Mission Systems Management Office at NASA Marshall. “This partnership not only accelerates cryogenics technology development but also prepares the Artemis Generation – the next generation of engineers and scientists – to drive future breakthroughs in spaceflight.”

NASA’s Human Lander Challenge is sponsored by the agency’s Human Landing System Program within the Exploration Systems Development Mission Directorate and managed by the National Institute of Aerospace.

For more information on NASA’s 2025 Human Lander Challenge, including team progress, visit the challenge website.

News Media Contact

Corinne Beckinger 
Marshall Space Flight Center, Huntsville, Ala. 
256.544.0034  
corinne.m.beckinger@nasa.gov 

Before yesterdayMain stream

NASA Readies Moon Rocket for the Future with Manufacturing Innovation

13 February 2025 at 10:29

NASA’s Artemis campaign will send astronauts, payloads, and science experiments into deep space on NASA’s SLS (Space Launch System) super heavy-lift Moon rocket. Starting with Artemis IV, the Orion spacecraft and its astronauts will be joined by other payloads atop an upgraded version of the SLS, called Block 1B. SLS Block 1B will deliver initial elements of a lunar space station designed to enable long term exploration of the lunar surface and pave the way for future journeys to Mars. To fly these advanced payloads, engineers at NASA’s Marshall Space Flight Center in Huntsville, Alabama, are building a cone-shaped adapter that is key to SLS Block 1B.

At NASA Marshall, the PLA engineering development unit is installed into the 4697-test stand for structural testing. It was then attached to the large cylindrical structure which simulates the Exploration Upper Stage interface. Load lines were then connected to the top of the PLA.The testing demonstrated that it can handle up to three times the expected load.
At NASA Marshall, the PLA engineering development unit is installed into the 4697-test stand for structural testing. It was then attached to the large cylindrical structure which simulates the Exploration Upper Stage interface. Load lines were then connected to the top of the PLA. The testing demonstrated that it can handle up to three times the expected load.
NASA/Samuel Lott

The payload adapter, nestled within the universal stage adapter sitting atop the SLS Block 1B’s exploration upper stage, acts as a connecting point to secure a large payload that is co-manifested – or flying along with – the Orion spacecraft. The adapter consists of eight composite panels with an aluminum honeycomb core and two aluminum rings.

Beginning with the Artemis IV mission, SLS Block 1B will feature a new, more powerful upper stage that provides a substantial increase in payload mass, volume, and energy over the first variant of the rocket that is launching Artemis missions I through III. SLS Block 1B can send 84,000 pounds of payload – including both a crewed Orion spacecraft and a 10-metric ton (22,046 lbs.) co-manifested payload riding in a separate cargo compartment – to the Moon in a single launch.

Artemis IV’s co-manifested payload will be the Lunar I-Hab, one of the initial elements of the Gateway lunar space station. Built by ESA (European Space Agency), the Lunar I-Hab provides expanded capability for astronauts to live, work, conduct science experiments, and prepare for their missions to the lunar surface.

Before the Artemis IV mission structure was finalized, NASA engineers needed to design and test the new payload adapter.

“With SLS, there’s an intent to have as much commonality between flights as possible,” says Brent Gaddes, Lead for the Orion Stage Adapter and Payload Adapter in the SLS Spacecraft/Payload Integration & Evolution Office at NASA Marshall.

However, with those payloads changing typically every flight, the connecting payload adapter must change as well.

“We knew there needed to be a lot of flexibility to the payload adapter, and that we needed to be able to respond quickly in-house once the payloads were finalized,” says Gaddes.

Working alongside the robots, NASA’s next generation of engineers are learning from experts with decades of manufacturing expertise as they prepare the metal honeycomb structure substrate. During production, the fingerprints of the engineers are imprinted where metal meets composite. Even after the finishing touches are applied, the right light at the right angle reveals the harmless prints of the adapter’s makers as it launches payloads on SLS that will enable countless discoveries.
Working alongside the robots, NASA’s next generation of engineers are learning from experts with decades of manufacturing expertise as they prepare the metal honeycomb structure substrate. During production, the fingerprints of the engineers are imprinted where metal meets composite. Even after the finishing touches are applied, the right light at the right angle reveals the harmless prints of the adapter’s makers as it launches payloads on SLS that will enable countless discoveries.
NASA/Samuel Lott

A Flexible Approach

The required flexibility was not going to be satisfied with a one-size-fits-all approach, according to Gaddes.

Since different size payload adapters could be needed, Marshall is using a flexible approach to assemble the payload adapter that eliminates the need for heavy and expensive tooling used to hold the parts in place during assembly.  A computer model of each completed part is created using a process called structured light scanning. The computer model provides the precise locations where holes need to be drilled to hold the parts together so that the completed payload adapter will be exactly the right size.

“Structured light has helped us reduce costs and increase flexibility on the payload adapter and allows us to pivot,” says Gaddes. “If the call came down to build a cargo version of SLS to launch 40 metric tons, for example, we can use our same tooling with the structured light approach to adapt to different sizes, whether that’s for an adapter with a larger diameter that’s shorter, or one with a smaller diameter that’s longer. It’s faster and cheaper.”  

NASA Marshall engineers use an automated placement robot to manufacture eight lightweight composite panels from a graphite epoxy material. The robot performs fast, accurate lamination following preprogrammed paths, its high speed and precision resulting in lower cost and significantly faster production than other manufacturing methods.

At NASA Marshall, an engineering development unit of the payload has been successfully tested which demonstrated that it can handle up to three times the expected load. Another test version currently in development, called the qualification unit, will also be tested to NASA standards for composite structures to ensure that the flight unit will perform as expected.

“The payload adapter is shaped like a cone, and historically, most of the development work on structures like this has been on cylinders, so that’s one of the many reasons why testing it is so important,” says Gaddes. “NASA will test as high a load as possible to learn what produces structural failure. Any information we learn here will feed directly into the body of information NASA has pulled together over the years on how to analyze structures like this, and of course that’s something that’s shared with industry as well. It’s a win for everybody.”

With Artemis, NASA will explore more of the Moon than ever before, learn how to live and work away from home, and prepare for future human exploration of the Red Planet. NASA’s SLS (Space Launch System) rocket, exploration ground systems, and Orion spacecraft, along with the human landing system, next-generation spacesuits, Gateway lunar space station, and future rovers are NASA’s foundation for deep space exploration.

News Media Contact

Jonathan Deal
Marshall Space Flight Center, Huntsville, Ala. 
256-544-0034 
jonathan.e.deal@nasa.gov

A Stellar Bouquet

14 February 2025 at 11:37
An image of 30 Doradus, or the Tarantula Nebula, looks like a bouquet of purple flowers with orange stamens. Types of data are represented in different colors: X-ray data from NASA’s Chandra X-ray Observatory is blue and green, optical data from NASA’s Hubble Space Telescope is yellow, and radio data from the Atacama Large Millimeter/submillimeter Array is orange. There is a purple and green bubble-like shape at bottom right. This is a superbubble.
X-ray: NASA/CXC/Penn State Univ./L. Townsley et al.; Infrared: NASA/JPL-CalTech/SST; Optical: NASA/STScI/HST; Radio: ESO/NAOJ/NRAO/ALMA; Image Processing: NASA/CXC/SAO/J. Schmidt, N. Wolk, K. Arcand

This image, released on Feb. 12, 2025, is the deepest X-ray image ever made of the spectacular star forming region called 30 Doradus. By combining X-ray data from NASA’s Chandra X-ray Observatory (blue and green) with optical data from NASA’s Hubble Space Telescope (yellow) and radio data from the Atacama Large Millimeter/submillimeter Array (orange), this stellar arrangement comes alive.

Otherwise known as the Tarantula Nebula, 30 Dor is located about 160,000 light-years away in a small neighboring galaxy to the Milky Way known as the Large Magellanic Cloud. Because it one of the brightest and populated star-forming regions to Earth, 30 Dor is a frequent target for scientists trying to learn more about how stars are born.

Learn more about this new image and what it reveals.

Image credit: X-ray: NASA/CXC/Penn State Univ./L. Townsley et al.; Infrared: NASA/JPL-CalTech/SST; Optical: NASA/STScI/HST; Radio: ESO/NAOJ/NRAO/ALMA; Image Processing: NASA/CXC/SAO/J. Schmidt, N. Wolk, K. Arcand

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