NASA’s Artemis IV astronauts will be the first to inhabit the Gateway lunar space station, opening the door to greater exploration of the Moon and paving the way to Mars. Gateway’s Power and Propulsion Element, which will make the station the most powerful solar electric spacecraft ever flown, takes shape at Maxar Space Systems. In lunar orbit, Gateway will allow NASA to conduct unique science and exploration while preparing astronauts to go to the Red Planet.

Technicians install key hardware on the element’s Propulsion Bus Module following installation of both electric propulsion and chemical propulsion control modules. The image highlights a propellant tank exposed on the right, positioned within the central cylinder of the element.  

The Power and Propulsion Element will launch with Gateway’s HALO (Habitation and Logistics Outpost) ahead of NASA’s Artemis IV mission. During Artemis IV, V, and VI, international crews of astronauts will assemble the lunar space station around the Moon and embark on expeditions to the Moon’s South Pole region.

The Power and Propulsion Element is managed out of NASA’s Glenn Research Center in Cleveland and built by Maxar Space Systems in Palo Alto, California.

Gateway is an international collaboration to establish humanity’s first lunar space station as a central component of the Artemis architecture designed to return humans to the Moon for scientific discovery and chart a path for the first human missions to Mars.

Through the Artemis campaign, NASA will send astronauts on missions to and around the Moon. The agency and its international partners report progress continues on Gateway, the first space station that will permanently orbit the Moon, after visiting the Thales Alenia Space facility in Turin, Italy, where initial fabrication for one of two Gateway habitation modules is nearing completion.

Leaders from NASA, ESA (European Space Agency), and the Italian Space Agency, as well as industry representatives from Northrop Grumman and Thales Alenia Space, were in Turin to assess Gateway’s HALO (Habitation and Logistics Outpost) module before its primary structure is shipped from Italy to Northrop Grumman’s Gilbert, Arizona site in March. Following final outfitting and verification testing, the module will be integrated with the Power and Propulsion Element at NASA’s Kennedy Space Center in Florida.

“Building and testing hardware for Gateway is truly an international collaboration,” said Jon Olansen, manager, Gateway Program, at NASA’s Johnson Space Center in Houston. “We’re excited to celebrate this major flight hardware milestone, and this is just the beginning – there’s impressive and important progress taking shape with our partners around the globe, united by our shared desire to expand human exploration of our solar system while advancing scientific discovery.”

To ensure all flight hardware is ready to support Artemis IV — the first crewed mission to Gateway – NASA is targeting the launch of HALO and the Power and Propulsion Element no later than December 2027. These integrated modules will launch aboard a SpaceX Falcon Heavy rocket and spend about a year traveling uncrewed to lunar orbit, while providing scientific data on solar and deep space radiation during transit.

Launching atop HALO will be ESA’s Lunar Link communication system, which will provide high-speed communication between the Moon and Gateway. The system is undergoing testing at another Thales Alenia Space facility in Cannes, France.

Once in lunar orbit, Gateway will continue scientific observations while awaiting the arrival of Artemis IV astronauts aboard an Orion spacecraft which will deliver and dock Gateway’s second pressurized habitable module, the ESA-led Lunar I-Hab. Thales Alenia Space, ESA’s primary contractor for the Lunar I-Hab and Lunar View refueling module, has begun production of the Lunar I-Hab, and design of Lunar View in Turin.

Northrop Grumman and its subcontractor, Thales Alenia Space, completed welding of HALO in 2024, and the module successfully progressed through pressure and stress tests to ensure its suitability for the harsh environment of deep space.

Maxar Space Systems is assembling the Power and Propulsion Element, which will make Gateway the most powerful solar electric propulsion spacecraft ever flown. Major progress in 2024 included installation of Xenon and chemical propulsion fuel tanks, and qualification of the largest roll-out solar arrays ever built. NASA and its partners will complete propulsion element assembly, and acceptance and verification testing of next-generation electric propulsion thrusters this year.

SpaceX will provide both the Starship human landing system that will land astronauts on the lunar surface during NASA’s Artemis III mission and ferry astronauts from Gateway to the lunar South Pole region during Artemis IV, as well as provide logistics spacecraft to support crewed missions.

NASA also has selected Blue Origin to develop Blue Moon, the human landing system for Artemis V, as well as logistics spacecraft for future Artemis missions. Having two distinct lunar landing designs provides flexibility and supports a regular cadence of Moon landings in preparation for future missions to Mars.

CSA (Canadian Space Agency) is developing Canadarm3, an advanced robotics system, and JAXA (Japan Aerospace Exploration Agency) is designing and testing Lunar I-Hab’s vital life support systems, batteries, and a resupply and logistics vehicle called HTV-XG.

NASA’s newest Gateway partner, the Mohammad Bin Rashid Space Centre (MBRSC) of the United Arab Emirates, kicked off early design for the Gateway Crew and Science Airlock that will be delivered on Artemis VI. The selection of Thales Alenia Space as its airlock prime contractor was announced by MBRSC on Feb. 4.

Development continues to advance on three radiation-focused initial science investigations aboard Gateway. These payloads will help scientists better understand unpredictable space weather from the Sun and galactic cosmic rays that will affect astronauts and equipment during Artemis missions to the Moon and beyond.

The Gateway lunar space station is a multi-purpose platform that offers capabilities for long-term exploration in deep space in support of NASA’s Artemis campaign and Moon to Mars objectives. Gateway will feature docking ports for a variety of visiting spacecraft, as well as space for crew to live, work, and prepare for lunar surface missions. As a testbed for future journeys to Mars, continuous investigations aboard Gateway will occur with and without crew to better understand the long-term effects of deep space radiation on vehicle systems and the human body as well as test and operate next generation spacecraft systems that will be necessary to send humans to Mars.

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.

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.

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

When NASA’s Artemis IV astronauts journey to the Moon, they will make the inaugural visit to Gateway, humanity’s first space station in lunar orbit. Shown here, technicians carefully guide HALO (Habitation and Logistics Outpost)—a foundational element of Gateway—onto a stand in the cleanroom at Thales Alenia Space in Turin, Italy. The element’s intricate structure, designed to support astronauts and science in lunar orbit, has entered the cleanroom after successfully completing a series of rigorous environmental stress tests.

In the cleanroom, technicians will make final installations before preparing the module for transport to the United States, a key milestone on its path to launch. This process includes installing and testing valves and hatches, performing leak checks, and integrating external secondary structures. Once these steps are finished, the module will be packaged for shipment to Gilbert, Arizona, where Northrop Grumman will complete its outfitting.

As one of Gateway’s four pressurized modules, HALO will provide Artemis astronauts with space to live, work, conduct scientific research, and prepare for missions to the lunar surface. The module will also support internal and external science payloads, including a space weather instrument suite attached via a Canadian Space Agency Small Orbital Replacement Unit Robotic Interface, host the Lunar Link communications system developed by European Space Agency, and offer docking ports for visiting vehicles, including lunar landers and NASA’s Orion spacecraft.

Developed in collaboration with industry and international partners, Gateway is a cornerstone of NASA’s Artemis campaign to advance science and exploration on and around the Moon in preparation for the next giant leap: the first human missions to Mars.