Periodic Reporting for period 1 - EARS (European Advanced Reusable Satellite)
Reporting period: 2023-01-01 to 2024-12-31
Space exploitation can be made more affordable - and sustainable - by the development of reusable, low-cost satellites. Presently, only very expensive or competitive services and platforms - covering the high-end sector of market - are available for research and commercial activities in space.
In the EARS project, we want to introduce the disruptive concept of ‘re-usability’ for small satellites to make Europe greener and more sustainable. We aim at the development of a low-cost, flexible spacecraft that can be easily produced in large numbers and reused, in order to support commercial activities and small scientific research in space at affordable costs. The EARS spacecraft is conceived to be launched in Low Earth Orbit to provide a platform for microgravity manufacturing and a variety of small experiments. The spacecraft is planned to complete its mission after several months, to perform a controlled re-entry and finally to be recovered in order to deliver its products and results back to the Earth. The spacecraft is also conceived to be re-used with minimal refurbishment, minimizing pollution, saving valuable materials and reducing the cost of access to space.
The main objective of the EARS project is to preliminarily design such reusable satellite and to develop the key technologies needed for its construction: a green propulsion system to steer the spacecraft, an inflatable heat shield to protect the spacecraft during the atmospheric re-entry and a reliable and precise Guidance, Navigation and Control (GNC) system to control the de-orbit, re-entry, descent and recovery phase of the spacecraft.
The long-term vision of the EARS project is a family of small satellites that can be launched and reused at a very competitive price without polluting the environment and wasting resources, both in Space and on Earth.
In the EARS project, we want to introduce the disruptive concept of ‘re-usability’ for small satellites to make Europe greener and more sustainable. We aim at the development of a low-cost, flexible spacecraft that can be easily produced in large numbers and reused, in order to support commercial activities and small scientific research in space at affordable costs. The EARS spacecraft is conceived to be launched in Low Earth Orbit to provide a platform for microgravity manufacturing and a variety of small experiments. The spacecraft is planned to complete its mission after several months, to perform a controlled re-entry and finally to be recovered in order to deliver its products and results back to the Earth. The spacecraft is also conceived to be re-used with minimal refurbishment, minimizing pollution, saving valuable materials and reducing the cost of access to space.
The main objective of the EARS project is to preliminarily design such reusable satellite and to develop the key technologies needed for its construction: a green propulsion system to steer the spacecraft, an inflatable heat shield to protect the spacecraft during the atmospheric re-entry and a reliable and precise Guidance, Navigation and Control (GNC) system to control the de-orbit, re-entry, descent and recovery phase of the spacecraft.
The long-term vision of the EARS project is a family of small satellites that can be launched and reused at a very competitive price without polluting the environment and wasting resources, both in Space and on Earth.
The work started with the definition of the concept of operation of the EARS spacecraft and its preliminary architecture in order to identify the main requirements, the additional modules - and relevant technical characteristics - needed to make the EARS spacecraft suitable for re-entry to the Earth. As a starting point for the EARS design, we used a commercial small satellite that had already flown in space, the MP42 by Kongsberg Nanoavionics. Then we studied how to develop and integrate all the identified additional modules (propulsion, heat-shield, recovery parafoil and GNC for re-entry) needed to make the EARS spacecraft able to go back to the Earth with its products and results. Subsequently, we studied the technical specifications of the EARS spacecraft and traded off its mass, power and volume to integrate the additional modules and to optimise its performance. The major modifications needed to adapt the MP42 satellite to the EARS spacecraft requirements and mission objectives were also identified and studied.
A modular propulsion module – based on the use of two green chemical propellants - was designed to fulfil the requirements of the EARS spacecraft. The thruster of the propulsion system was constructed and successfully tested in a dedicated infrastructure against the EARS spacecraft requirements, suggesting also its reusability as a viable option.
An innovative heat-shield, based on inflatable technology, was preliminarily designed: it is made of a rigid nose and a three-layered inflatable system that protects the satellite during the re-entry. The materials needed for its construction were selected and extensively tested in relevant environment using the Plasmatron, a device able to reproduce the harsh environment experienced by the EARS satellite during the re-entry phase.
Novel guidance, navigation and control solutions to make the EARS able to re-entry the Earth atmosphere and to be recovered were studied. The needed sensors and actuators were identified and the critical algorithms and procedures were determined and developed. The algorithms were also successfully tested by means of a comprehensive test campaign that allowed to evaluate the landing accuracy for the EARS spacecraft. The results confirmed the feasibility of retrieving the EARS spacecraft by mid-air recovery using a helicopter.
Finally, EARS research and development activities were supported by addressing the future exploitation of the results, which was pursued through the analysis of the EARS business case, the generation of sustainable business model canvasses and the production of development roadmaps for each investigated technology. A detailed cost analysis, based on a gradual introduction of the reusability features in the platform design, demonstrated the achievement of significant savings compared to the traditional single-use spacecrafts.
A modular propulsion module – based on the use of two green chemical propellants - was designed to fulfil the requirements of the EARS spacecraft. The thruster of the propulsion system was constructed and successfully tested in a dedicated infrastructure against the EARS spacecraft requirements, suggesting also its reusability as a viable option.
An innovative heat-shield, based on inflatable technology, was preliminarily designed: it is made of a rigid nose and a three-layered inflatable system that protects the satellite during the re-entry. The materials needed for its construction were selected and extensively tested in relevant environment using the Plasmatron, a device able to reproduce the harsh environment experienced by the EARS satellite during the re-entry phase.
Novel guidance, navigation and control solutions to make the EARS able to re-entry the Earth atmosphere and to be recovered were studied. The needed sensors and actuators were identified and the critical algorithms and procedures were determined and developed. The algorithms were also successfully tested by means of a comprehensive test campaign that allowed to evaluate the landing accuracy for the EARS spacecraft. The results confirmed the feasibility of retrieving the EARS spacecraft by mid-air recovery using a helicopter.
Finally, EARS research and development activities were supported by addressing the future exploitation of the results, which was pursued through the analysis of the EARS business case, the generation of sustainable business model canvasses and the production of development roadmaps for each investigated technology. A detailed cost analysis, based on a gradual introduction of the reusability features in the platform design, demonstrated the achievement of significant savings compared to the traditional single-use spacecrafts.
The EARS project goes beyond the current state-of-the-art under several respects. Currently, no reusable satellite is operational in the world: only capsules and spaceplanes can be used as unmanned commercial reusable space systems capable of flying and recovering the results of small research experiments or the products of commercial activities in space. Capsules, however, have limited flexibility and capability, while spaceplanes are very expensive to build and operate, covering a valuable - yet complementary - high-end sector of the market. EARS has investigated the development of an affordable, reusable small spacecraft, flexible for different tasks, and easily produced in large numbers thanks to its modular architecture that exploits many components or modules already present in commercial satellites.
Furthermore, EARS has contributed to the maturation of relevant key technologies needed for the construction of this innovative spacecraft, namely: (1) a greener, flexible propulsion system; (2) an innovative thermal protection system to ensure atmospheric re-entry of the EARS satellite; (3) precise and reliable guiding systems for controlled satellite re-entry to the Earth.
Finally, since the EARS spacecraft is conceived to be used for microgravity research, technological tests and in-space manufacturing, indirect countless impacts are expected on the scientific, technological and educational fields - also not directly related with space - because of all the research that can be made possible by the EARS spacecraft.
Furthermore, EARS has contributed to the maturation of relevant key technologies needed for the construction of this innovative spacecraft, namely: (1) a greener, flexible propulsion system; (2) an innovative thermal protection system to ensure atmospheric re-entry of the EARS satellite; (3) precise and reliable guiding systems for controlled satellite re-entry to the Earth.
Finally, since the EARS spacecraft is conceived to be used for microgravity research, technological tests and in-space manufacturing, indirect countless impacts are expected on the scientific, technological and educational fields - also not directly related with space - because of all the research that can be made possible by the EARS spacecraft.