Mechanical Engineering Aspects of the Space Shuttle Orbiter–Design, Manufacture and Operation

Abstract

The designers of the Space Shuttle were faced with engineering challenges for which little or no precedent existed, and which required unique and innovative mechanical engineering approaches for their solution. Before the Shuttle Program, all manned space vehicles were designed for high reliability single mission capability. In contrast, the Shuttle Orbiter has the requirements of reusability for 100 missions, in order to minimize operational costs, and has to be highly weight efficient to meet vehicle performance requirements. The Space Shuttle is a versatile aerospace vehicle in that it takes off like a rocket, manoeuvres in Earth orbit like a spacecraft, and lands like an airplane. In performing these functions, the Shuttle undergoes a wide spectrum of aerodynamic, acoustic, and inertial loadings, along with exposure to the temperature extremes of space, plus a severe aerothermodynamic heating environment during entry. These environments, along with unique mission requirements, resulted in design challenges of unprecedented complexity. The space vehicle that evolved has provided a flexibility never before achieved in space operations, and allows space to be treated as a resource, rather than as a hostile, uninviting environment. This paper provides an overview of the Space Shuttle Program, details of some typical mechanical engineering challenges that evolved during the development phase of the Program, and some operational performance observations. In particular, the paper focuses on activities associated with the Orbiter's structure, mechanical systems and thermal protection systems. The innovative design solutions that were developed for the Shuttle, and their outstanding performance during the flight test program, lend confidence in man's engineering ability to achieve a permanent presence in space.