NASA’s recent advancements in rocket assembly techniques mark a significant leap forward in the preparation for upcoming Artemis Moon missions. These advancements, taking place at the Kennedy Space Center’s Vehicle Assembly Building (VAB) in Florida, are set to revolutionize how the Space Launch System (SLS) rockets are constructed and assembled.

The VAB’s High Bay 2 has been equipped with state-of-the-art tooling to aid in the vertical integration of the SLS core stage. This development was prominently showcased in mid-December when teams successfully suspended the fully assembled core stage 225 feet in the air within the high bay. This procedure is a prelude to stacking it on mobile launcher 1, which allows for concurrent solid rocket booster stacking in High Bay 3 for the Artemis II mission.

The relocation to High Bay 2 is a strategic move, providing NASA and Boeing technicians with comprehensive, 360-degree access to the core stage, both internally and externally. This access is critical for efficient assembly and maintenance. Futuramic Tool and Engineering, a company based in Michigan, was instrumental in designing and constructing the Core Stage Vertical Integration Center tool. This tool is essential for keeping the core stage upright during the integration process.

Chad Bryant, deputy manager of the NASA SLS Stages Office, highlighted the benefits of early completion of High Bay 2 tooling, initially slated for Artemis III. By accelerating this process, NASA is positioned to complete the core stage work ahead of schedule, thus facilitating an earlier transition of the core stage for Artemis II into the comprehensive integrated stack in High Bay 3. This advancement allows engineers to refine their techniques in rotating, lifting, and maneuvering the core stage within the high bay.

This strategic shift effectively doubles the usable space within the VAB, granting engineers simultaneous access to both High Bay 2 and High Bay 3. It also liberates space at NASA’s Michoud Assembly Facility in New Orleans, enabling continued work on future SLS core stages.

High Bay 2 holds a rich history of supporting NASA’s exploration endeavors. During the Apollo era, it was the site for the assembly of the Saturn V rocket. In the Space Shuttle Program, it served multiple roles, including external tank checkout and storage, as well as an additional storage area for the shuttle.

Under the new assembly model set to commence with Artemis III, major structures for the SLS core stage will continue to be fully produced and manufactured at NASA Michoud. After the completion of manufacturing and the application of the thermal protection system, the engine section will be shipped to Kennedy for final outfitting.

A notable development occurred on July 23, 2024, when the 212-foot-tall SLS core stage for Artemis II was transported from a horizontal to a vertical position in High Bay 2 at Kennedy Space Center. This shift grants NASA and Boeing technicians comprehensive access to the core stage, both internally and externally.

Steve Wofford, manager of the SLS Stages Office, emphasized the significance of Core Stage 3, marking a pivotal shift in how core stages are constructed. The vertical capability in High Bay 2 allows for parallel processing from top to bottom of the stage, significantly enhancing efficiency. This new capability streamlines final production efforts, enabling the team to access the stage comprehensively.

The fully assembled core stage for Artemis II, which arrived at Kennedy in a horizontal position, was recently elevated into the newly outfitted high bay. Meanwhile, teams at NASA Michoud are outfitting the remaining core stage elements for Artemis III and preparing to horizontally join them. The four RS-25 engines for the Artemis III mission, completed at NASA’s Stennis Space Center in Mississippi, are slated for transportation to Kennedy in 2025. Additionally, major core stage and exploration upper stage structures are underway at NASA Michoud for Artemis IV and subsequent missions.

NASA’s Artemis mission aims to achieve remarkable milestones, including landing the first woman, the first person of color, and its first international partner astronaut on the Moon. The SLS is a cornerstone of NASA’s deep space exploration efforts, alongside the Orion spacecraft, supporting ground systems, advanced spacesuits and rovers, the Gateway orbiting the Moon, and commercial human landing systems. The SLS stands out as the sole rocket capable of sending Orion, astronauts, and supplies to the Moon in a single launch.

These advancements in rocket assembly not only enhance NASA’s operational efficiency but also pave the way for future exploration endeavors, reaffirming the agency’s commitment to pushing the boundaries of space exploration.
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