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A research piece I wrote for Contrary Research in March 2024 by Ashley Fong
Since the inaugural launch of the Space Shuttle in 1981, humanity's venture into space has undergone a transformation, transitioning from primarily government-led missions to an era dominated by private enterprises. This shift has sparked a wave of innovation and competition, enabling faster technological advancements and dramatically reducing the costs associated with space access. NASA’s Shuttle Program played a crucial role in establishing the core technologies necessary for life and work in extraterrestrial environments. In the years that followed, SpaceX has been at the forefront of revolutionizing space access, with significant advancements in rocket technology and cost reductions moving closer to the possibility of multi-planetary existence. This new age of space exploration is marked by a dramatic decrease in launch costs, from the Space Shuttle's $65,000 per kilogram to SpaceX's Falcon Heavy, which has reduced the price to around $1,400 per kilogram.
https://lh7-rt.googleusercontent.com/docsz/AD_4nXfzyswHZtUXq4XrwYI7tGSX6i0c7kG632I-p9oukNYzfcaahCO2XKemJ_v9QKOo8hmrfuFYjhbBoDtJZYHl6F2Mj_oOcnaagwvdUGDyMz4WvJsdZjKMJj5LHxIFJpfkxfvvw5FNxW1qrQb4BfcQk3sYwNCt?key=nQEsRg46QGmHAx17kGdaaA
Data source: Our World In Data (2024)
With funding surpassing millions of dollars, research initiatives on the International Space Station (ISS) have been pivotal in exploring the distinct advantages of microgravity environments. Earth’s gravitational pull often introduces impurities in materials through natural processes, such as sedimentation and crystallization. In contrast, the expanse of space presents an untainted laboratory setting, where scientists can observe material behavior unencumbered by such terrestrial constraints. The construction of structures in space not only promises more precise and efficient methods of assembly but also minimizes potential material deformation and damage that might otherwise occur. This line of research carries significant implications, extending from the refinement of glass used in fiber optic cables—a cornerstone of global telecommunications—to the enhancement of protein structures in pharmaceutical development, potentially elevating both the effectiveness and safety of medical treatments.
Varda Space Industries is aiming to redefine in-space manufacturing, developing a seamless system that not only facilitates production of materials in a microgravity environment but also ensures their safe return to Earth. Varda integrates advanced capsules for manufacturing with re-entry modules designed for reuse, streamlining the journey of raw materials into space and back. By prioritizing the commercial viability of these space-manufactured materials, Varda is set to revolutionize various industries on Earth, marking a significant leap forward in both space technology and terrestrial applications. This focus on making space-manufactured materials commercially viable is set to significantly impact various sectors on Earth, heralding advancements in accessible space technology.
Varda was founded in November 2020 by Will Bruey (CEO), Delian Asparouhov (Chairman and President), and Daniel Marshall (former Chief Scientist).
Bruey has been captivated by space from an early age and worked at SpaceX for 5 years. His role was the Lead Hardware Development Engineer on the Dragon spacecraft where his expertise was in hardware engineering and mission control, especially in the complexities of reentry. His career also includes a stint at Bank of America and launching his venture firm, Also Capital.
According to an interview on the Pomp Podcast, Asparouhov has been fascinated with space since his first year of high school. After leaving MIT in 2013, he founded Nightingale, a healthcare app for autism care, which was part of Y Combinator's Spring 2014 cohort but eventually shut down. Throughout his undergraduate education and early career, he remained curious about space, believing that the space industry would eventually be commercialized, and eventually set off to work in venture capital. Asparouhov worked as Chief of Staff to Keith Rabois and later as a General Partner at Khosla Ventures, where he was promoted to Principal in 2019. Shortly after, he was a principal at Founder’s Fund, Peter Thiel’s SF-based venture fund. Drawing parallels between SpaceX’s impact on commercial space and AWS’s on SaaS, he later co-founded Varda at Founder’s Fund, aiming to innovate in-space manufacturing.
Marshall served as Varda’s co-founder and past Chief Scientist until 2022. He currently works at Draper as a Senior Optical Development Engineer and previously worked as a Senior Sensor Engineer at Physical Optics. At Physical Optics, Marshall was the principal investigator for the $5M Fiber Optic Production project, leading the design and integration of modules on the ISS to manufacture ZBLAN optical fiber, which could surpass terrestrial silica fiber in performance when produced in microgravity. Rounding out the team’s technical core includes CTO Nicholas Cialdella, who previously served as a senior avionic systems engineer at SpaceX, and Head of Hardware Development Richard Wissemann, who previously led hardware at Apple, Blue Origin, and SpaceX.
In a podcast interview with Payload, Asparouhov and Bruey shared the origin story of how Varda began. Asparouhov's concept of industrializing space, which he originally formulated as an investment thesis, was sparked by observing the Falcon rocket's repeated launches and landings. Curious about the durability of such technology, he would chat with his friends from SpaceX about the “wear and tear” and the potential for a spacecraft like the Starship to launch and land up to 40 times. His friends working at SpaceX, would assure him that reusable rockets were becoming a reality, a significant advance in space technology. However, Asparouhov noticed that most operations were still confined to the International Space Station (ISS), with many hesitant to operate independently due to concerns about re-entry and recovery. Motivated to explore beyond these limitations, Asparouhov began discussions with members of the SpaceX Dragon spacecraft team, sharing his vision and searching for a potential co-founder. During this process, he was encouraged to meet Bruey, who was already considering starting his own venture. After chatting, Bruey booked a flight to California immediately to join Asparouhov. Their initial meeting, which Bruey described to be similar to a "blind date," laid the groundwork for what would soon become Varda.
Varda's manufacturing process in orbit is structured into four primary stages. Initially, a rocket equipped with their payload must achieve a successful launch from the ground and enter orbit. Upon reaching orbit, the launch vehicle is jettisoned, and a satellite bus takes over to ensure that all onboard systems are functioning correctly throughout the orbit duration. Manufacturing then commences within a specially-designed module that is capable of producing various high-value products in microgravity conditions. After the manufacturing process is complete, the critical final stage involves the re-entry capsule, which safely transports the finished products back to Earth.
https://lh7-rt.googleusercontent.com/docsz/AD_4nXd0DX3dehxrO_n97bTmy1CbLfxOMOpNLyodURpKLHYH2nG9ZJoo9uO6QhNI9vTDoSnQNtXARe4TkeQKPfRbcblHoKfC5aSWjZNpG1Qajbo96PYhKL2CqSye6_-Vvm4x5LxGOPx1A5S1yKXZ2pSXRr42_u2K?key=nQEsRg46QGmHAx17kGdaaA
The first four spacecraft by Varda are part of the Winnebago series, built in collaboration with Rocket Lab, which provides the bus base integrated with Varda’s manufacturing module. ****The bus base serves as the structural and functional foundation for the spacecraft while Varda contributes its proprietary manufacturing module, designed to enable the production of various materials in space. The Winnebago Series spacecraft are designed to operate autonomously and independently, capable of conducting missions and returning payloads without the need for space station support such as the International Space Station, allowing them to bring back their payload without relying on external assistance. The spacecraft is free-flying, featuring a ground-based landing design for their re-entry module, prioritizing cost-efficiency and safety.
https://lh7-rt.googleusercontent.com/docsz/AD_4nXeCWoDvItsAjtHt6-ehoi7Wfooff_xC0xSEm_3eMPcT4EUabRdo2Vtsa44HQCs-zoL50Fj3HrHvKhDJKAuAVups13m8glRJKLLRUMwarnD1Ewpu7ZeXnbiu-1chv5Ojh5ODwN1oOIXsvapj3cCaaSYBaAKY?key=nQEsRg46QGmHAx17kGdaaA