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so

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very rarely do you get the opportunity

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to kind of literally from the ground up

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put together a factory whose sole

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purpose is to go make history and do

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exciting things for

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not just nasa but for american for the

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whole world we're in the process of

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getting the factory ready for sls

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production and in that process there's a

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series of new tools that we've been

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installing in the factory

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now we have not just put in new tool and

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there's some legacy tooling that we're

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using most of the external tank

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buildings are being reused we have a lot

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of construction going on for those

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getting ready for a rocket that's

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the same diameter but a little bit

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longer not only are we using the legacy

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knowledge the lessons learned we're also

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incorporating new technologies

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the the tool today

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is in the vertical friction stir welding

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center and it's its job is to produce

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the

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tank that will be stacked and that is

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going to be the tool that joins every

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panel on every barrel for the rocket

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this device will actually do the weld in

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a single pass and then also do

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inspections so these are the large

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barrel sections of the the core stage

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that will be the foundation or the

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beginning rocket that will actually take

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our crews beyond the moon and really

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here at marshall we've designed the

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interface hardware in between the orion

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capsule and that upper stage the msa i

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think is a great example of a couple

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things one it's actually a piece of

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hardware that we're flying on an early

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test but we're also going to fly for the

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long term so this is the same design

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that we'll use when orion's on the sls

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and we're actually flying people today

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we've been taking the two unique pieces

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of hardware

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that are supposed to have a common

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interface basically lowering them

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together bolting and making sure that

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they fit well we're going to test a lot

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of the key systems

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on orion and also for sls with the upper

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stage of the msa that are going to be

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used when we fly people into deep space

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most recently we've been involved with

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nasa with the sls development using our

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unique forming technology

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along with our other core processes in

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terms of machining welding heat treating

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and inspection technologies

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really is a one-stop shop is what you

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right behind me you have the first cap

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first weld development cap i think he

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called the weld confidence cap the

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production order started deliveries in

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2014.

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spincraft also builds the domes for the

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upper stage delta iv vehicle which will

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be used for the eft-1 flight as well as

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the first two production flights of the

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sls program

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[Music]

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for the sls pdr our primary role was the

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overall communication and outreach

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support that we provide back to todd

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may's office for sls we provide all of

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the communication support for that

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particular team that program and project

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well it's a preliminary design review

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and primarily it's a technical review to

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make sure that the design is acceptable

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and the appropriate level of maturity

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there's a lot of discussions there's a

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lot of meetings across the board from

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technical cost schedule performance data

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safety human factors it's like a health

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check on the program

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those of us that are working on the

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program

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we're got our head down we're we're

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doing our pieces

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and sometimes when you're working real

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close to things you don't necessarily

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see everything so there's so many moving

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parts and so many things going on at the

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agency

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as well as the center that to show

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people that we are moving in the right

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direction to pull together the complete

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story of where we are as a program

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watching at it from a higher level

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headquarters viewpoint it's just

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gratifying to see the

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the accomplishments that the teams have

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[Music]

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for ct2 we're doing modifications not

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only to make it last another 20 years

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but also to upgrade the load capacity

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the main project we're working on right

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now is the roller replacement project

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which is the roller assembly it's

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actually the rollers the shafts the

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bearings that support the crawler

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actually if you go there you'll see

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trucks a and c jacked up and on

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cribbing and that's the first time in

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the career crawler it's ever actually

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been jacked off the ground so the guys

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have easy access to the

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rollers roller assemblies and they're in

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the process now of removing the old

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rollers old shafts and old parts

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once they've

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done the line boring that's when they'll

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start assembling the new rollers and the

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new shafts and the new bearings and the

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new sleeves new adapters new plates so

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there's quite a bit of work and that

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work will go well from august through

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october so there's going to be a lot of

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trucks delivering a lot of steel

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we started actually the new design for

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flame deflector

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as well as a refurbishment of the flame

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trench and that's because of the new

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requirements for

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sls and commercial vehicles

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we've started the demolition of the

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flame deflector

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we've got concerns of you know due to

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age and the

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debonding of the flame trench structure

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this would possibly be a safety hazard

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for um you know our new program and

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that's why we had to go in and do a new

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design

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and refurbish this flame deflector and

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these pieces here they're not just one

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program it's not just one mission it's

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part of a capability that will enable

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this country to be a leader in space to

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continue to take people from the earth

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well beyond low earth orbit out into

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deep space and this is the hardware that

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will do that over multiple decades in

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the future

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[Music]

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so the work that's been accomplished so

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far is primarily structural type work

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right it's a lot of drilling a lot of

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secondary structure installation

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mechanical structures the support

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structure the next step is starting to

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install the subsystems when we actually

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perform the welding on tubes for

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propulsion in the environmental controls

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and life support systems

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those have to be at a higher level of

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cleanliness when you look at the

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facility there are these very large

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walls that are that are on the perimeter

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of the structure itself and and those

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are called hepa filter walls we can

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perform clean room work for the tubing

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concurrently

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while on the outside doing more standard

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clean room so our goal is next summer

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sometime to turn the vehicle over early

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summer over to the ground operations

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organization so they can start their

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processing

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well the service module is attached

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below the crew module and it has the

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prop tanks and the engine

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radiators

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solar panels a service module all came

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in pieces

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[Music]

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there's 49 composite panels on the sm

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the actual structure itself is aluminum

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that's the core skeleton where these

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composite panels were attached to

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after the cm releases and we stand

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returns to earth the sm will just burn

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up with the with the upper stage of the

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delta iv

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we performed two primary tests so far

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the proof pressure test which is just

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the pressure vessel and that is that is

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put into the proof pressure cell it's

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pressurized and a relatively high

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pressure we're testing how well the

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vehicle was built and then the follow-on

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test is the static loads test where the

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vehicle goes through eight different

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loads test cases and so the vehicle is

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put under under pressure it's put under

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tension it's put under compression the

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whole intent is to simulate similar

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conditions that the vehicle would

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experience say in flight in launch in

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and also in landing and recovery

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[Music]

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we usually get the abort motor first and

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for this mission the abort motor is

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inert uh being a nominal flight we're

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going to have instrumentation on it to

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again understand more about the loads

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and environments that we expect to see

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in flight but it will be an inert

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propellant that's cast into the motor

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this time we got the jettison motor next

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and that's the only live component of

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this vehicle

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we do a nominal jettison the jettison

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motor fires the last separates from the

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cm and the cm continues on its mission

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you know one of the challenges of any

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new system is understanding the loads as

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you send up through the atmosphere and

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the dynamics the acoustics and

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we'll be able to gather a lot of that

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the back shell

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it looks though it looks the same as

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what we flew on shuttle it is different

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we kind of took the best aspects and put

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them together to meet lockheed martin's

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requirements for for the orion capsule

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two major things we're trying to

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accomplish here one of them is to

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prevent micro meteorite damage when

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we're on orbit for long duration the

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other wood of course is is the reentry

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aspect the skin that you see on the

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capsule what you would see on orbit sits

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on top of a composite substrate what we

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call the back shell panel

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that that when combined together gives

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you the complete back shell there's some

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sections that have some very complex

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geometry so what we're going to do for

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the first time is take a substrate

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that's built by lockheed martin and put

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it together with

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the tiles that are manufactured by

258
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jacobs and and validate the fit up

259
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like any test vehicle you're heavily

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instrumented we're going to come back

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with a tremendous amount of data on how

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how the system performs

263
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[Music]

264
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this first flight test of orion is

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really to to understand how the heat

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shield performs and that heat shield's

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being going final manufacturing at

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textron's had a long association with

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nasa and working in the space area for

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space protection

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[Music]

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the technology today has advanced

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tremendously

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our manufacturing technology has

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advanced but ironically we're still

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using

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a material that has proven itself for

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the last 40 years mavcote is a very

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efficient ablater and as an ablator what

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it does it allows us to protect the

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capsule from the high heating that

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occurs during re-entry there is no

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material non-ablator material that can

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handle that kind of heat you have to

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shed away

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the heat basically what you're doing is

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you peel off the layers of the heat

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shield you're taking heat with it when

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we apply avco to the heat shield

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we bond the honeycomb onto the carrier

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structure and then we inject the avcode

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ablative material into the cells the

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honeycomb acts as a crack arrester and

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gives it rigidity and and strength as a

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whole

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we know we're on the critical path for

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the orion program and so our employees

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are literally working all hours all days

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of the week to make sure that we hit our

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schedule we know there'll be more heat

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shields coming and we're very excited

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about that our job is to make sure

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[Music]

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the development programs i find uh

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just awesome because this is where

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you're coming up with the new ideas

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you're creating the new vehicles you're

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you're pushing you're pushing the

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boundaries in essence you can feel that

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we're gonna go do this the hardware is

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starting to come the orion hardware is

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getting ready for its first flight test

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the excitement is here we are really

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ready to get going so we are far from

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being out of space we are really getting

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ready to go into space that's so

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rewarding to see our focus into what's

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next because this really is our future

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i know the day that we fly this thing

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there are going to be thousands of

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people that are going to be excited that

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are working on this and the nasa

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workforce and the contractor workforce

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we're going to be proud of the work that

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this team has done and i think we're

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going to be proud of our country too

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it's going to be pretty exciting time

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i'm ready to build a rocket and we are