With a heavy lift launch vehicle as the centerpiece of our nation's next exploration architecture's infrastructure, the Advanced Concepts Office at NASA's Marshall Space Flight Center initiated a study to examine the utilization of elements derived from a heavy lift launch vehicle for other potential launch vehicle applications. The premise of this study is to take a vehicle concept, which has been optimized for Lunar Exploration, and utilize the core stage with other existing or near existing stages and boosters to determine lift capabilities for alternative missions. This approach not only yields a vehicle matrix with a wide array of capabilities, but also produces an evolutionary pathway to a vehicle family based on a minimum development and production cost approach to a launch vehicle system architecture, instead of a purely performance driven approach. The upper stages and solid rocket booster selected for this study were chosen to reflect a cross-section of: modified existing assets in the form of a modified Delta IV upper stage and Castor-type boosters; potential near term launch vehicle component designs including an Ares I upper stage and 5-segment boosters; and longer lead vehicle components such as a Shuttle External Tank diameter upper stage. The results of this approach to a modular launch system are given in this paper.

The Marshall Space Flight Center Advanced Concepts Office (ACO) has the leading role for NASA's preliminary conceptual launch vehicle design and performance analysis. Over the past several years the ACO Earth-to-Orbit Team has evaluated thousands of launch vehicle concept variations for a multitude of studies including agency-wide efforts such as the Exploration Systems Architecture Study (ESAS), Constellation, Heavy Lift Launch Vehicle (HLLV), Heavy Lift Propulsion Technology (HLPT), Human Exploration Framework Team (HEFT), and Space Launch System (SLS).NASA plans to continue human space exploration and space station utilization. Launch vehicles used for heavy lift cargo and crew will be needed. One of the current leading concepts for future heavy lift capability is an inline one and a half stage concept using solid rocket boosters (SRB) and based on current Shuttle technology and elements. Potentially, the quickest and most cost-effective path towards an operational vehicle of this configuration is to make use of a demonstrator vehicle fabricated from existing shuttle assets and relying upon the existing STS launch infrastructure. Such a demonstrator would yield valuable proof-of-concept data and would provide a working test platform allowing for validated systems integration. Using shuttle hardware such as existing RS-25D engines and partial MPS, propellant tanks derived from the External Tank (ET) design and tooling, and four-segment SRB's could reduce the associated upfront development costs and schedule when compared to a concept that would rely on new propulsion technology and engine designs.There are potentially several other additional benefits to this demonstrator concept. Since a concept of this type would be based on man-rated flight proven hardware components, this demonstrator has the potential to evolve into the first iteration of heavy lift crew or cargo and serve as a baseline for block upgrades. This vehicle could also serve as a demonstration and test platform for the Orion Program. Critical spacecraft systems, re-entry and recovery systems, and launch abort systems of Orion could also be demonstrated in early test flights of the launch vehicle demo. Furthermore, an early demonstrator of this type would provide a stop-gap for retaining critical human capital and infrastructure while affording the current emerging generation of young engineers opportunity to work with and capture lessons learned from existing STS program offices and personnel, who were integral in the design and development of the Space Shuttle before these resources are no longer available.The objective of this study is to define candidate launch vehicle demonstration concepts that are based on Space Shuttle assets and determine their performance capabilities and how these demonstration vehicles could evolve to a heavy lift capability to low earth orbit.

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The Advanced Concepts Office at NASA's George C. Marshall Space Flight Center conducted a high-level analysis of various air launch vehicle configurations, objectively determining maximum launch vehicle payload while considering carrier aircraft capabilities and given dimensional constraints. With the renewed interest in aerial launch of low-earth orbit payloads, referenced by programs such as Stratolaunch and Spaceship2, there exists a need to qualify the boundaries of the trade space, identify performance envelopes, and understand advantages and limiting factors of designing for maximum payload capability. Using the NASA/DARPA Horizontal Launch Study (HLS) Point Design 2 (PD-2) as a pointof-departure configuration, two independent design actions were undertaken. Both designs utilized a Boeing 747-400F as the carrier aircraft, LOX/RP-1 first stage and LOX/LH2 second stage. Each design was sized to meet dimensional and mass constraints while optimizing propellant loads and stage delta V (ΔV) splits. All concepts, when fully loaded, exceeded the allowable Gross Takeoff Weight (GTOW) of the aircraft platform. This excess mass was evaluated as propellant/fuel offload available for a potential in-flight propellant loading scenario. Results indicate many advantages such as payload delivery of approximately 47,000 lbm and significant mission flexibility including variable launch site inclination and launch window. However, in-flight cryogenic fluid transfer and carrier aircraft platform integration are substantial technical hurdles to the realization of such a system configuration.