SSC16-II-02

LauncherOne: Virgin Galactic's Dedicated Launch Vehicle for Small Satellites

A.C. Charania, Steve Isakowitz, Barry Matsumori, Will Pomerantz, Mandy Vaughn, Hanna Kubiak, David Caponio
Virgin Galactic
4022 E. Conant St., Long Beach, CA 90808 USA; +1-404-931-7980
[email protected]

ABSTRACT
Virgin Galactic, the world's first commercial spaceline, is developing a space transportation service to provide an
affordable, reliable, and responsive dedicated ride to orbit for smaller payloads. No longer will small satellite users
be forced to make a choice between accepting the limitations of flight as a secondary payload, paying dramatically
more for a dedicated launch vehicle, or dealing with the added complexity associated with export control
requirements and international travel to distant launch sites. Virgin Galactic's satellite launch vehicle,
“LauncherOne,” is a two-stage, air-launched liquid propulsion (LOX/RP) rocket. This system is designed to conduct
operations from a variety of locations, allowing customers to select various launch azimuths and increasing available
orbital launch windows. In response to strong commercial demand, Virgin Galactic has increased the capability of
LauncherOne so that it will now be capable of launching of approximately 300 kg into the standard Sun-
Synchronous Orbit most commonly desired by small satellite missions, or more than 400 kg into lower inclination
orbits.

INTRODUCTION launched from a 747-400 carrier aircraft, LauncherOne

is the space access service that will accelerate the small
Satellite technology has spent decades after the launch
of Sputnik and Explorer I getting bigger, heavier, and satellite revolution.
more expensive. But recently, the rise of Cubesats and
OVERVIEW
microsatellites has meant that commercial satellite start-
ups, universities, schools, and even crowdfunding As seen in Fig. 2, the LauncherOne system is a two
campaigns can put their own satellites into space. stage launch vehicle composed of mostly composite
However, small satellites need small satellite launch primary structures with pump-fed first and second stage
vehicles that are optimized to the needs of these engines. The first stage has a single 73,500 lbf (vac)
spacecraft. Among these needs are cost-effective, LOX/RP-1 rocket engine called the “NewtonThree.”
frequent rides to space in their desired orbits as primary The second stage has a single 5,000 lbf (vac) LOX/RP-
payload. 1 rocket engine called the “NewtonFour.” Both the
NewtonThree and the NewtonFour are highly reliable
Virgin Galactic has invested in the team, technologies, liquid rocket engines being designed, tested, and built
and facilities required to build just such a customer- by Virgin Galactic.
focused launch service, LauncherOne (see Fig. 1). Air-

Figure 1: LauncherOne Small Satellite Launch Vehicle Service

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 Figure 2: LauncherOne Overview

For West Coast continental U.S. launches, most flexible and responsive launch vehicle to offer
LauncherOne can deliver approximately 300 kg of affordable, dedicated launches to smaller satellites.
payload into the standard Sun-Synchronous Orbit most
commonly desired by small satellite missions. To low The LauncherOne program is based on an in-house
Earth orbits from the East Coast of the continental U.S. design, development, test, manufacturing, integration,
the system will be capable of launching over 400kg of and operations approach. Virgin Galactic has made key
payload. investments in multiple technology areas such as
cryogenic composite tanks, pump-fed booster and
As an air-launched system, LauncherOne can optimize upperstage engines, and an autonomous flight safety
each mission to customer requirements by operating system. Having successfully completed test campaigns
from any of a variety of launch sites independent from for pressure-fed demonstrator engines for both the
the fixed, often congested, launch ranges and upper and booster stage of LauncherOne, Virgin
corresponding real-time launch constraints such as Galactic is now testing the NewtonThree and
weather. NewtonFour engines, which have been undergoing
rigorous testing on two new state-of-the-art test stands
PROGRAM STATUS designed, assembled, and installed by Virgin Galactic
With full, private funding already committed to the in Mojave, CA, USA. In addition to testing of the
program, a dedicated and world-class team of over 200 engines, Virgin Galactic has successfully undertaken
experienced aerospace professionals hard at work, and a hardware-in-the-loop testing of LauncherOne’s tanks,
state-of-the-art 14,000 square meters (150,000 square pressurization systems, avionics, and other critical
foot) manufacturing and design facility in Long Beach, subsystems.
California, LauncherOne remains on target to be the

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Virgin Galactic purchased a 747-400 last year Table 1: LauncherOne Capabilities
(coincidentally nicknamed “Cosmic Girl”). In late
Service Value
2015, the aircraft was put through a successful “D
check,” also known as a heavy maintenance check. The Payload Payload Capability
aircraft is currently undergoing modification to • Up to 300 kg / 661 lbm to 500 km / 270 nmi
Sun Synchronous Orbit (SSO)
strengthen the left wing area such that it will be able to
• Up to 500 kg / 1100 lbm to 200 km / 108 nmi
carry the 55,000 lbs LauncherOne rocket. Virgin circular 28.5 degree inclination Low Earth Orbit
Galactic is also making updates to the power and (LEO)
communications routings throughout the aircraft. The • Due to LauncherOne’s high degree of
Virgin Galactic team is also developing a new pylon to customization, payload capabilities are best
calculated for each customer based on their
attach the rocket to the carrier aircraft. specific requirements.
Payload Dynamic Volume
LauncherOne was announced in 2012, with the program
• 1359 mm / 53.5 inch constant cylindrical
evolving since that time. In 2015, Virgin Galactic diameter
announced a larger LauncherOne service that more than • 2283 mm / 89.9 inch constant cylindrical length
doubled the previous payload performance utilizing • 3632 mm / 143 inch overall payload fairing
upgraded first and second stage engines, along with a envelope length
change of the carrier aircraft from the WhiteKnightTwo Launch • Up to 1000 km and greater depending upon
to the 747-400. Virgin Galactic upgraded the Altitudes/ payload and inclination
NewtonOne and NewtonTwo engines, which were Inclinations • West Coast US (Mojave Air and Space Port):
pressure-fed, with newer pump-fed versions. 60 to 102 degrees inclination
NewtonOne and NewtonTwo were pathfinder engines • East Coast US (Shuttle Landing Facility): 28.5
to 55 degrees inclination
used as part of LauncherOne’s development process.
Payload • Initial operations based on West Coast United
CAPABILITIES Delivery States with payload integration in Virgin Galactic
and FAITH facility Level 8 clean room, Mojave, CA
LauncherOne missions are highly customized to suit Integration • Customer satellites mated with a payload
each customer’s specific requirements. Operating adapter and encapsulated in the payload fairing
independently of the rest of the vehicle
commercially through the FAA, LauncherOne operates
• Options exist for receipt of pre-encapsulated
independently of many of the external factors that can payloads
delay ground based launches: weather, offline radar
Regulatory • U.S. Federal Aviation Administration AST Part
tracking assets, boats in the launch pad stay out zone, Approach 431 Launch License
and traffic jams on the increasingly crowded Eastern • Includes immediate West Coast launches and
and Western ranges. Table 1 provides a summary of the future East Coast launches
capabilities of the LauncherOne service. • Additional launch site options are planned
Orbital • Capability for second stage deorbit mission
LAUNCH SITE AND MISSION PROFILES Debris profiles
Approach
Virgin Galactic has completed launch assessments for
the primary launch site of the Mojave Air and Dispenser • LauncherOne’s various payload bolted interface
Options patterns will meet the ESPA -class and ESPA -
Spaceport (MHV) in California and for a variety of Grande class configurations
operating locations including the Shuttle Landing • Includes a conical payload adapter with
Facility (SLF) at the Kennedy Space Center (KSC) in interface diameter of 985.7 mm / 38.81 inches;
Florida. Virgin Galactic is prepared to obtain approvals other interfaces possible including ESPA
to operate in locations other than Mojave based on standard 609.6 mm / 24 inches or 381 mm / 15
inches diameters, custom diameters available
customer interest. upon request
• Standard payload separation systems that may
The baseline West Coast U.S. flight profile would drop be supported include but are not limited to the
the LauncherOne launch vehicle over the Pacific following: PSC MLB, SNC QwkSep, SV clamp
Ocean, tens of kilometers from the California coastline, band, FANTM-LiTE, FANTM-RiDE, FANTM-
after a flight of approximately 30 minutes from Mojave. RAiL; custom systems available upon request
Virgin Galactic has analyzed different flight tracks for • Standard dispensers that may be supported
include but are not limited to the following: Cal-
additional drop points off the California coast that may Poly P-POD, NLAS, ISIS Quad Pack/EZ-POD,
be of interest for other missions. For East Coast U.S. PSC 3U CSD, PSC 6U CSD, PSC 12U CSD,
launches, the drop point will be tens of kilometers from PSC 27U CSD, Tyvak 6U, Tyvak Rail-POD
the coastline depending upon the selected takeoff • Secondary payloads can be manifested and
managed directly by Virgin Galactic or via
runway. selected payload brokers or aggregators

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PERFORMANCE will be attached to the standard payload adapter
Orbital payload performance from multiple launch sites interface with the primary payload mounted on top.
is provided in Figs. 3 and 4. LauncherOne is designed
The LauncherOne fairing incorporates standard payload
to meet FAA regulations that require a maximum orbit
access doors and Radio Frequency (RF) windows near
life time of 25 years for an upper stage left at an altitude
the base of the fairing composite structure. The fairing
less than 2000 km. Meeting this requirement
can be further modified according at the customer’s
necessitates a third disposal burn for orbital altitudes
request in order to relocate or provide additional
above 625 km. Above 1000 km, a progressively higher
payload access doors and RF windows.
level of propellant is needed for the upper stage
disposal resulting in a longer burn time as shown in the ACCOMMODATIONS AND ENVIRONMENTS
last knee of the payload performance curve.
Virgin Galactic’s LauncherOne service includes
PAYLOAD payload processing, integration, and performance of the
actual launch mission. Virgin Galactic is open to
As seen in Fig. 5, LauncherOne offers one of the largest
tailoring analysis and test requirements, based on
payload envelopes in the industry for this class of
current industry standards, to the customer’s mission.
dedicated small satellite launch. LauncherOne
Virgin Galactic’s LauncherOne service supports certain
accommodates a wide range of payload masses up to a
payload consumables including cold gas,
500 kg / 1100 lbm payload for a 185 km / 100 nmi
xenon/krypton, and various “green” monopropellants.
circular orbit with a center of mass 1524 mm / 60
Customers may be able to conduct payload testing or
inches above the payload adapter interface. integration activities at the Launch Site as subject to
LauncherOne has the ability to multi-manifest satellites applicable operational and regulatory requirements.
if desired by the customer, employing the large fairing
LauncherOne’s payload environments are comparable
volume in a variety of ways to best meet mission
to other air-launch orbital launch vehicles. As with such
requirements. For multi-satellite missions with primary
vehicles, many of the most demanding flight
and secondary payloads, a secondary payload adapter

Figure 3: LauncherOne Orbital Inclination Capability from Various United States Launch Sites

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 Figure 4: LauncherOne Orbital Payload Delivery Performance

Figure 5: LauncherOne Payload Dynamic Envelope and Sample Payloads Configurations

environments occur during the captive carry phase of During captive carry, the fairing is purged with
flight. Virgin Galactic predictions for payload temperature-controlled gaseous nitrogen. The bulk air
environments are updated periodically. temperature in the payload fairing will drop as the
aircraft climbs and is highly dependent on the
The primary payload thermal environment during all environmental conditions, time of day, time of year,
ground storage, handling, encapsulation, and integration and flight path. At the customer’s request, electrical
operations prior to carrier aircraft taxi is maintained at power is provided to the payload during captive carry.
21 ± 3.5 degrees Celsius (69.8 ± 7 degrees Fahrenheit).

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The inner wall temperature on the fairing is expected to LauncherOne propulsion systems, a full avionics
rise until fairing jettison. The inner wall temperature is facility, and also a full suite of quality and verification
expected to climb to between 60 and 94 degrees Celsius systems. There is also a large assembly area to
(140 and 201 degrees Fahrenheit) prior to fairing accommodate high volume manufacture, up to 20 to 30
jettison during second stage burn. Options are available rockets a year. Virgin Galactic also leverages its exiting
at the customer’s request to limit the effects of the hot footprint in Mojave, California for liquid propulsion,
fairing inner wall. The time varying fairing inner wall composite tank, and overall stage testing (see Figs. 7
temperature distribution is highly dependent on the and 8). As seen in Fig. 9, payload delivery/integration
trajectory and the initial conditions just prior to release along with flight operations for the initial West Coast
from the carrier aircraft. U.S. launch service will utilize Virgin Galactic’s
existing facilities at the Mojave Air & Space Port such
FACILITIES as Virgin Galactic’s Final Assembly, Integration and
The LauncherOne program combines the use of Test Hangar (FAITH).
existing Virgin Galactic facilities along with new
Virgin Galactic is also leveraging external partners to
dedicated facilities aimed at producing reliable low cost
assist in 747-400 aircraft maintenance and
launch vehicles. The program is highly vertically
modification. As shown in Figs. 10 and 11, it has
integrated with the vast majority of the design,
utilized ST Aerospace and its US affiliate company VT
engineering, manufacturing, integration, assembly, and
San Antonio Aerospace for a D-level heavy
test performed in Long Beach, California (see Fig. 6).
maintenance check. Also, Virgin Galactic selected L-3
This facility includes an extensive composite
Platform Integration to work on the wing modification
manufacturing area with all the tools to build at high
of the dedicated mothership for the LauncherOne
rate. It includes an extensive Computer Numerical
program (see. Fig. 12).
Control (CNC) metal shop to build and form the

Figure 6: LauncherOne Rocket Factory for Design, Development, and High Rate Production (Long Beach,
California)

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 Figure 7: Virgin Galactic Necker Liquid Propulsion Test Site (Mojave, California)

Figure 8: NewtonThree (N3) Development Engine Hot Fire Test on Necker Test Stand Two (Mojave,
California)

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 Figure 9: LauncherOne Payload Integration and Flight Facility: Visualization of Virgin Galactic 747-400
“Cosmic Girl” Outside Existing FAITH Facility (Mojave, California)

Figure 10: LauncherOne 747-400 Carrier Aircraft “Cosmic Girl”: Post D check and Pre Wing Modification (VT
San Antonio Aerospace, San Antonio, Texas). Photo Credit: Astro95Media.

Figure 11: Sir Richard Branson with 747-400 “Cosmic Figure 12: Virgin Galactic “Cosmic Girl” 747-400
Girl” and LauncherOne Model (San Antonino, Texas) Arriving at L-3 Platform Integration for Wing
Modification (Waco, Texas)

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