Cygnus is typically launched using its parent company's Antares rocket from the Wallops Flight Facility in Virginia, however it is able to fly on other launch vehicles. After the failure of an Antares rocket destroyed Cygnus CRS Flight 3 and damaged the Wallops facility, two Cygnus missions were launched with Atlas V rockets in 2015 and 2016. Additionally, two Cygnus missions have launched on the Falcon 9 rocket in 2024 with one more scheduled to launch in 2025, operated by CRS competitor SpaceX.
Then-NASA Administrator Charles Bolden (third from left) in front of the Cygnus spacecraft in May 2012
After the retirement of the Space Shuttle was announced, NASA began to look for commercial space launch companies who could fly cargo to the ISS. In early 2006, the agency started its Commercial Orbital Transportation Services (COTS) program, where it would help fund the development of cargo spacecraft after a competitive process. SpaceX and Rocketplane Kistler won contracts in the COTS program, however Rocketplane Kistler failed to meet several financial milestones and on 18 October 2007, NASA announced it would terminate its contract and re-award it after a second competition.[5][6]
Orbital Sciences Corporation participated in this second round, proposing a largely "off-the-shelf" design. The spacecraft, named Cygnus, would be built around a service module based on Orbital's Star Bus, a satellite bus in use since 1997, which would be attached to a pressurized cargo module built by Thales Alenia Space, which had also built the MPLM cargo module used by the Space Shuttle, the cargo module for the European ATV spacecraft and several permanent modules on the ISS.[7]
Cygnus was awarded a COTS contract worth $170 million in February 2008, which was later increased to $288 million. On 23 December 2008, NASA awarded Orbital Sciences a $1.9 billion contract under the Commercial Resupply Services (CRS) program. Under this contract, Orbital Sciences agreed to deliver up to 20 tons of cargo to the ISS through 2016 in eight Cygnus spacecraft flights.[8]
To propel Cygnus into space, Orbital developed the Antares rocket, which also leveraged lower-cost, off-the-shelf parts and designs. Construction and design of the first stage was subcontracted to Ukrainian companies and used refurbished NK-33 engines, remnants of the Soviet N1 moon rocket. The second stage was the Castor 30, which Orbital had previously used on another rocket project (the Minotaur-C) and was based on a Peacekeeper ICBM first stage.
The first Cygnus flight was originally planned to occur in December 2010, but was repeatedly delayed.[9][10] The Antares made its maiden flight lifting a payload mass simulator to low Earth orbit on April 21, 2013. On September 18, 2013, Antares successfully launched a Cygnus spacecraft on a flight test to rendezvous with the International Space Station.[11] On 12 January 2014, the first scheduled Cygnus resupply mission arrived at the space station; the capsule carried Christmas presents and fresh fruit for the astronauts. Its arrival was delayed, first by the need to repair the station, and then by frigid weather at the launch site and solar flares that forced postponements.[11][12]
With the December 2015 launch of Orb CRS-4 on Atlas V, the enhanced version of Cygnus made its debut. While it was planned from the beginning to fly on the fifth mission, the Orb CRS-3 failure and subsequent move to Atlas V meant a delay. However, lessons learned on packing and the extra capabilities of the Atlas allowed payload to be increased to 3,500 kg (7,700 lb).[13]
Design
A scale drawing of the Standard (left) and Enhanced (right) Cygnus
The Cygnus spacecraft consists of two basic components: the Service Module (SM) and the Pressurized Cargo Module (PCM).
The SM was based on prior products developed by Orbital including the GEOStar and LEOStar (collectively known as Star Bus) satellite buses and the Dawn spacecraft. It has a gross mass of 1,800 kg (4,000 lb), 32 thrusters for attitude control and one BT-4 main engine[14] fuelled with 800 kg (1,800 lb) of hypergolic propellants, hydrazine and nitrogen tetroxide.[15][16] The SM is capable of producing up to 4 kW of electrical power via two solar arrays.[17][18]
The Standard Cygnus being unberthed from the Harmony module
The PCM is manufactured by Thales Alenia Space in Turin, Italy. The first "Standard" PCMs had a length of 5.14 meters (16.9 ft), a payload capacity of 2,000 kilograms (4,400 lb), and a pressurized cargo volume of 18.9 cubic metres (670 cu ft).[17]
The fourth and all subsequent Cygnus spacecraft are the "Enhanced" variant.[18] These have a stretched PCM with a length of 6.39 meters (21.0 ft), a payload capacity of 3,500 kilograms (7,700 lb), an increase of 32%, and a pressurized cargo volume of 27 cubic metres (950 cu ft), an increase of 19.5%.[19] To launch the added weight, Orbital used the more powerful Castor 30XL solid-fuel rocket as a second-stage.
Starting in mid-2025, a further enlarged "Mission B" Cygnus will be introduced with a length of 7.89 meters (25.9 ft), a payload capacity of 5,000 kilograms (11,000 lb), an increase of 19.5%, and a pressurized cargo volume of 36 cubic metres (1,300 cu ft), an increase of 15.5%.[3]
Cygnus does not provide cargo return capability. However, it can be loaded with obsolete equipment and trash which will burn up as the Cygnus makes a destructive reentry.[20]
An earlier proposed version of Cygnus would have replaced the PCM with the Unpressurized Cargo Module (UCM), based on NASA's ExPRESS Logistics Carrier, and would have been used to transport unpressurized cargo, such as ISS Orbital Replacement Units.[9][21] Another proposed variant would have replaced the PCM with the Return Cargo Module (RCM), which would have allowed Cygnus to return cargo to Earth.[9]
In August 2023, Northrop Grumman announced a further enlarged Mission B version of Cygnus, with a 1.5 m (4.9 ft) stretch to the payload module and payload mass increased to 5,000 kg (11,000 lb). This version is expected to enter service with the NG-23 mission in 2025 (the first to use the new Antares 330 launch vehicle).[3]
Lunar Gateway module variant
In August 2019, NASA decided to sole source its design for the Minimal Habitation Module (Habitation and Logistics Outpost, or HALO) of the Lunar Gateway to Northrop Grumman Innovation Systems, which offered a minimalist 6.1 m (20 ft) by 3 m (9.8 ft) design based directly on the Enhanced Cygnus, as well as a larger 7 m (23 ft) by 4.4 m (14 ft) design[22][23] having radial docking ports, body-mounted radiators (BMRs), batteries and communications antennas added on the outside. Northrop Grumman Innovation Systems opted to build the minimalist design, which offered the advantage of component compatibility and expedited testing of life support systems on existing Cygnus spacecraft.[24][25] On 5 June 2020, NASA awarded Northrop Grumman Innovation Systems a $187 million contract to complete the preliminary design of HALO. NASA will sign a separate contract with Northrop for the fabrication of the HALO, and for integration with the Power and Propulsion Element (PPE), being built by Maxar.[24][25]
First Cygnus mission, first mission to rendezvous with ISS, first mission to berth with ISS, second launch of Antares. Docking to ISS delayed due to a computer data link problem,[31] which was later was resolved.[32]
First Antares launch to use Castor 30XL upperstage. Suffered a catastrophic anomaly resulting in an explosion shortly after launch, damaging launch pad. Contents of the cargo included food and packages for the crew, parts, experiments, and the Arkyd-3 flight test system from Planetary Resources.
First flight of Enhanced Cygnus spacecraft. Due to damage at launch pad after the explosion of the Antares rocket carrying Orb-3, Orbital contracted with United Launch Alliance to launch this Cygnus on an Atlas V rocket from Cape Canaveral Air Force Station. First of three missions to fly on an Atlas V rocket.
First a commercial vehicle to perform ISS reboosting when, at 20:25 UTC on July 10, 2018, Cygnus's main engine was fired for about 50 seconds. Raised ISS altitude by about 295 ft (90 m).[48]
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