Varda gets reentry license for space manufacturing capsule

After months of effort and one rejected application, Varda Space Industries said Feb. 14 it has received a license from the Federal Aviation Administration to return a capsule from its first mission. The FAA’s Office of Commercial Space Transportation issued a reentry license for Varda’s W-Series 1 spacecraft. The license will allow the company to land a capsule from that spacecraft at the Utah Test and Training Range (UTTR) and neighboring Dugway Proving Ground west of Salt Lake City. Varda said that reentry is scheduled for Feb. 21. “We’ve been working closely with our government partners and our satellite partner, Rocket Lab, to ensure a safe and compliant return from space,” Varda said in a statement. “Today we’re excited to announce the FAA has approved a re-entry attempt for Feb 21st.” Varda launched W-Series 1, its first spacecraft, in June on the SpaceX Transporter-8 rideshare mission. The company performed experiments to test the production of crystals in microgravity, which would be returned to Earth in a capsule developed by Varda attached to the Rocket Lab-produced spacecraft. The company had hoped to return the capsule as early as mid-July, but said then was still working with the FAA to obtain a reentry license, required for any commercial spacecraft returning to Earth. One issue the company said it was facing was that it was the first company seeking a reentry license under new regulations called Part 450 intended to streamline the licensing process, but which some companies reported difficulties adjusting to.

Varda Space Industries' W-Series 1 spacecraft includes a capsule designed to return pharmaceutical experiments. Credit: Varda Space Industries

In October, the company said it had come close in early September to getting an FAA reentry license as well as securing approval from the U.S. Air Force, which operates UTTR. “It was ultimately a coordination problem amongst three different groups that had not worked through this operation before,” Delian Asparouhov, co-founder of Varda, said in an interview at the time.

“This is the first time in our nation’s history that the FAA has granted a Part 450 reentry license, and licensed a commercial entity to land a spacecraft on U.S. soil,” Varda said in its statement about the license. “We are incredibly proud to have this opportunity with our government partners, and appreciate their dedication to safe innovation in the United States.”

The conical capsule, about 90 centimeters across and 74 centimeters high, weighs less than 90 kilograms, as described in a section of an environmental assessment about the reentry. The capsule landing area is an ellipse 45 by 35 kilometers covering parts of UTTR and the neighboring Dugway Proving Ground. The main spacecraft would also reenter and burn up, with only small pieces surviving reentry.

According to the environmental assessment, several ranges run by the Department of Defense in Arizona, Nevada, New Mexico, Oregon and Utah were considered as potential landing sites for the capsule, as they offered controlled access not available elsewhere, such as public lands maintained by the Bureau of Land Management. Only the UTTR/Dugway met all the requirements to safely return the capsule.

The assessment noted that non-U.S. locations were ruled out from consideration for this mission because of the “time, uncertainty, and complexity associated with obtaining the necessary agreements” between the U.S. and the foreign government for the landing, as well as challenging shipping the capsule back to the United States.

However, Varda announced in October an agreement with Southern Launch, a spaceport operator based in Adelaide, Australia, to host capsule returns at the Koonibba Test Range northwest of Adelaide. That range could be used for Varda’s second mission, scheduled for as soon as mid-2024.

Varda waiting on FAA license to return space manufacturing capsule

A startup that launched its first mission to test space manufacturing technologies last month is waiting on a Federal Aviation Administration license to be able to bring what it produced back to Earth. Varda Space Industries launched its first spacecraft, called W-Series 1, on the SpaceX Transporter-8 rideshare mission June 12, to test the ability to produce crystals in microgravity. Those crystals would be brought back to Earth in a reentry capsule set to return as soon as July 17. However, Varda said July 20 it was delaying the capsule’s return as it works with “our government partners to ensure everyone is fully ready.” The company didn’t elaborate on those issues or estimate when it would be ready to return the capsule. In a July 24 interview, Delian Asparouhov, co-founder of Varda, said the company was still working with the Federal Aviation Administration’s Office of Commercial Space Transportation for a reentry license for the spacecraft. That office, best known for licensing commercial launches, is also responsible for overseeing reentries by commercial spacecraft. A key issue, he said, is that Varda is the first to seek a reentry license under new FAA regulations known as Part 450. Those regulations were enacted by the FAA more than two years ago to streamline the launch and reentry licensing process. “I think a lot of the collaborations that we’ve had with the FAA have been trailblazing, and we recognize that, given we’re the first, we set the standard for what future Part 450 reentry looks like,” he said. Varda started discussions with the FAA in early 2021, shortly after the company’s founding.

Varda Space Industries' W-Series 1 spacecraft includes a capsule designed to return pharmaceutical experiments. The company is waiting on an FAA license to be able to return the spacecraft. Credit: Varda Space Industries

For the commercial launch industry, the Part 450 regulations have become an area of concern. Only a handful of Part 450 launch licenses have been issued to date as the FAA begins a transition to the new regulations, but those licenses have taken longer to complete than expected, in some cases missing a 180-day statutory deadline. Industry officials raised the issue at a July 13 hearing of the House Science Committee and at a July 11 meeting of an FAA advisory group, the Commercial Space Transportation Advisory Committee.

“Part 450 is a new regulatory regime that obviously comes with challenges,” he said. “But we’re also excited to hopefully help set the standard for what this should look like on the reentry side of things.”

Asparouhov said his company didn’t have a firm date for returning the 120-kilogram capsule but was making plans for a potential reentry in early to mid August. In addition to the FAA reentry license, Varda has to coordinate with the FAA’s air traffic organization on airspace closures and with the Defense Department’s Utah Test and Training Range, where the capsule will land.

There are no pressing technical issues that require the capsule to return by a specific deadline, but the company would like to bring the capsule back sooner rather than later. “There’s no reason why you’d want to add on risk by extending a mission beyond what it was designed for,” he said. “Our goal is to bring it home as quickly as possible given the positive business and technical implications for it.”

During its time in orbit, the spacecraft tested the ability to produce crystals of a drug called ritonavir used to treat HIV/AIDS. Telemetry from the spacecraft indicates the experiment went as planned, but the company wants to get the crystals back to verify it did produce the expected crystals.

Varda has “a lot of very eager customers” in the pharmaceutical industry interested in the results from this mission, Asparouhov said. The company will also sell data collected during the capsule’s return to Earth for government customers.

“We are a startup and delaying day by day burns capital day by day,” he said. “I prefer to make progress in shorter periods of time.”

The company is working on its second spacecraft that, like the first, will be manufactured by Rocket Lab using that company’s Photon bus. That spacecraft will launch on the Transporter-10 rideshare mission late this year or early next year.

Future spacecraft will carry more sophisticated equipment for producing crystals for pharmaceutical applications. “This first mission on board had the equivalent of a toaster in terms of like pharma manufacturing capabilities. We definitely need to build the convection oven, the blender and the mixer, a ton more capabilities to satisfy our clients,” he said. “But we’re super happy that we managed to make a little bit of toast.”