Module Design and Business Plans
Bigelow Aerospace anticipates that its inflatable modules will be more durable than rigid modules. This is partially due to the company's use of several layers of vectran, a material twice as strong as kevlar, and also because, in theory, flexible walls should be able to sustain micrometeoroid impacts better than rigid walls. In ground-based testing, micrometeoroids capable of puncturing standard ISS module materials penetrated only about half-way through the Bigelow skin. Operations director Mike Gold commented that Bigelow modules also wouldn't suffer from the same local shattering problems likely with metallic modules. This could provide as much as 24 hours to remedy punctures in comparison to the more serious results of standard ISS skin micrometeoroid damage.
Expected uses for Bigelow Aerospace's expandable modules include microgravity research and development and space manufacturing. Other potential uses include variable-gravity research—for gravity gradients above microgravity including moon (0.16 g) and Mars (0.38 g) gravity research; space tourism—such as modules for orbital hotels; and space transportation—such as components in spaceships for Moon or Mars manned missions.
On April 10, 2007, Bigelow Aerospace announced business plans to offer (by 2012) a four-week orbital stay for US$15 million, with another four weeks for an additional $3 million. An entire orbital facility could also be leased for $88 million a year, or half a facility for $54 million a year. Speaking during a teleconference organised by the Commercial Spaceflight Federation in February 2010, Bigelow announced a new price of $23 million for a 30 day stay on a Bigelow habitat. That price covers everything including transport, training, and consumables.
In 2010, Bigelow proposed conceptual designs for expandable habitats that would be substantially larger than the BA 330, previously its largest at 330 cubic metres (11,700 cu ft) habitat volume. Contingent on NASA going forward with a super heavy lifter, the proposed concept would include "expandable habitats offering 2,100 cubic meters of volume — nearly twice the capacity available on the International Space Station", and another providing 3,240 cubic metres (114,400 cu ft).
In 2010, Bigelow Aerospace began building a large production facility in North Las Vegas, Nevada to produce the space modules. The 181,000 square feet (16,800 m2) facility will include three production lines for three distinct spacecraft, doubling the amount of floor space at Bigelow, and transitioning the focus from research and development, with an existing workforce of 115, to production. Bigelow expected to hire approximately 1,200 new employees to staff the plant, with production commencing in early 2012.
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