Haven-1 Achieves Key Testing Milestone: Advancing Commercial Space Station Development

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Vast is making significant progress toward establishing itself as a commercial space station provider with its Haven-1 project. The company is actively working to bring an operational private space station into orbit, positioning itself ahead of other commercial efforts in the sector. The recent successful qualification testing of Haven-1’s primary structure represents an essential step toward its deployment, setting Vast apart from other competitors working toward similar goals.

With a focus on rapid iteration, real-world manufacturing experience, and a commitment to ensuring continuous human presence in low-Earth orbit (LEO), Haven-1 is being developed with an ambitious timeline. The progress made so far demonstrates a structured approach to space station development, emphasizing the importance of hands-on engineering, rigorous testing, and maintaining a tight schedule.

The Vision Behind Haven-1

Vast launched the Haven-1 project with three key objectives:

• Competing for NASA’s Commercial Low Earth Orbit Destination (CLD) Phase II contract
• Building an experienced team with the capability to design and manufacture crewed space systems
• Ensuring a continuous U.S. and international presence in LEO after the International Space Station (ISS) is retired

Aiming for NASA’s CLD Phase II

NASA’s CLD program is designed to transition LEO operations from the ISS to commercially operated space stations. While several companies were awarded initial funding, Vast adopted a different approach. Instead of relying solely on concept designs, the company is actively developing and testing a fully functional space station ahead of NASA’s selection process. By the time NASA chooses its partner for Phase II, Vast plans to have already demonstrated operational capabilities with Haven-1.

The experience gained from Haven-1 will be directly applied to Haven-2, Vast’s proposed successor station. Having built, tested, and operated a crewed space station, Vast intends to enter the Phase II selection process with more direct flight heritage and hands-on experience than any other contender.

Establishing Real-World Manufacturing and Testing Capabilities

Unlike other projects that focus on completing design milestones before encountering manufacturing constraints, Vast integrates real-world testing and iteration into its development process. This approach has already resulted in significant design refinements.

One example is the decision to switch from stainless steel to aluminum as the primary structural material for Haven-1. Originally planned as a stainless steel structure, the company encountered manufacturing and supply chain challenges, leading them to evaluate an alternative. Through a direct comparison between both materials, aluminum was selected due to its performance and ease of manufacturing.

A similar approach is applied across all mission-critical subsystems, including avionics, life support, power systems, control moment gyroscopes (CMGs), and propulsion. These technologies are being matured in-house and with industry partners to ensure reliability in space.

Preparing for a Post-ISS Era

With the ISS set to retire in 2030, NASA and international partners need a viable replacement to maintain human presence in LEO. Vast plans to have Haven-2 ready for operations by 2028, ensuring a seamless transition between the ISS and next-generation space stations.

By leveraging the design, facilities, and workforce developed for Haven-1, Vast believes it can deploy Haven-2 efficiently and at a reduced cost. The company emphasizes speed and cost-effectiveness as key differentiators, positioning itself as a strong candidate to fill the upcoming gap in LEO research and human habitation.

Haven-1 Primary Structure Development

One of the major milestones achieved recently was the successful qualification testing of Haven-1’s primary structure. Vast completed this key structural component in record time, marking the first U.S.-built space station primary structure in over two decades.

The manufacturing process for Haven-1 began with a Pathfinder article produced between November 2023 and June 2024. This prototype allowed the team to refine tooling and fabrication techniques before constructing the full-scale primary structure.

In July 2024, Vast began working on the primary structure qualification article. By January 2025, the flight-ready primary structure was in production, with completion expected by mid-2025. The ability to manufacture space station hulls in under six months demonstrates Vast’s efficiency and sets a new benchmark in the industry.

All structural elements of Haven-1 underwent extensive testing to validate their performance under simulated launch and on-orbit conditions. Key components tested included:

• The hatch
• Domed window pressure pane
• Forward bulkhead
• Launch vehicle separation system flange
• International Docking Adapter (IDA) flange

To support testing, Vast developed a custom test stand replicating Haven-1’s launch environment. This system incorporated pressurization using dry nitrogen, hydraulic actuators to simulate launch forces, and multiple strain gauge channels to monitor structural integrity.

Qualification Testing Results

On January 15, 2025, the primary structure qualification article was shipped to Vast’s Mojave, California, test facility for evaluation. The test campaign began on January 31, marking the company’s first full-scale vehicle test program.

Testing included:

• A decay leak check at 0.2 barD, which passed successfully
• A proof test pressurization to 1.8 barD (26 psig), during which:
• No structural changes or leaks were detected
• Pressure was held steady for five hours
• Leak rates remained within acceptable limits
• Strain gauges remained within allowable thresholds

Following the proof test, the structure was maintained at 3 psi (0.2 bar) for 48 hours to further evaluate leak rates. The results exceeded NASA’s leak rate requirements, demonstrating the integrity of the structure.

The test campaign followed NASA Standard 5001, ensuring compliance with stringent safety and performance criteria.

Next Steps

With the successful completion of Haven-1’s primary structure qualification testing, Vast now moves into the next phase of the project. The remaining test campaign will involve:

• Applying simulated launch and orbital forces using hydraulic actuators
• Conducting structural load tests under pressurized conditions
• Simulating flight environments to assess long-term durability

In parallel, the Haven-1 flight primary structure is being finalized. Once completed in July 2025, the station will move into full integration and subsystem testing.

Updated Haven-1 Timeline

Vast has refined its launch schedule based on progress made to date. The updated milestones include:

• July 2025 – Completion of flight primary structure manufacturing and testing
• July – December 2025 – Integration of vehicle systems and subsystem testing
• January – March 2026 – Environmental testing, including acoustic and vibration assessments
• April – May 2026 – Launch campaign preparations
• May 2026 – Haven-1 launch
• May – June 2026 – Uncrewed orbital commissioning
• June 2026 – First crewed mission, with four astronauts aboard a SpaceX Dragon for a two-week stay

Summary

Vast is on track to become the first company to launch and operate a commercial space station. With the successful completion of Haven-1’s primary structure qualification testing, the company has demonstrated its ability to rapidly design, manufacture, and test space station components.

By maintaining an aggressive development timeline and focusing on real-world manufacturing challenges, Vast is positioning itself as a leader in commercial space station development. If all goes as planned, Haven-1 will be operational by mid-2026, marking a new era for private spaceflight and research in low-Earth orbit.

Last update on 2025-12-21 / Affiliate links / Images from Amazon Product Advertising API