NASA Explores Mars Sample Return Mission Approaches with Commercial Partners

NASA’s ambitious Mars Sample Return (MSR) mission is undergoing significant reassessment as the agency collaborates with industry experts to explore innovative solutions aimed at reducing costs and accelerating timelines.

In June 2024, NASA selected seven companies to conduct 90-day studies, each valued at up to $1.5 million, to evaluate alternative approaches that could refine or completely overhaul the current MSR architecture.

The current MSR plan, which involves returning samples collected by the Perseverance rover, is estimated to cost up to $11 billion and may not deliver the samples back to Earth until 2040. Recognizing the need for a more efficient approach, NASA has turned to the private sector for fresh ideas.

“That architecture, we know, is too expensive. NASA has asked the industry how we can improve this,” - Jim Green, Former NASA Chief Scientist

Revisiting the Mars Ascent Vehicle (MAV)

One of the primary focuses of the study is the Mars Ascent Vehicle (MAV), a critical component of the MSR mission. The MAV, as currently envisioned, is a two-stage rocket that stands about three meters tall and uses solid motors to launch the collected samples from the Martian surface into orbit.

“We’re going to study how to best optimize going smaller,” - David McGrath, Northrop Grumman Senior Fellow

Northrop Grumman is exploring ways to enhance the interstage section between the two stages, which houses the attitude control systems. “Our path forward is to take all of our knowledge of all of these systems and our heritage products and blend that into a size range where we think the mission will be affordable,” McGrath added, though he did not specify the exact mass reduction target.

Simplifying the Earth Return Orbiter (ERO)

Quantum Space, a startup with a focus on cislunar spacecraft development, is examining another crucial aspect of the MSR mission: the final return of samples to Earth. The ERO is designed to retrieve the sample canister, known as the OS, from Mars orbit and transport it back to Earth.

Quantum Space is leveraging its cislunar capabilities to propose a novel approach. Instead of bringing the OS directly to Earth, the ERO would deliver it to lunar orbit, where a version of Quantum Space’s Ranger spacecraft would retrieve it for the final leg of the journey. This method could lead to a simpler design for both the ERO and the OS.

A possible solution would see the sample canister transferred to a spaceplane for a runway landing on Earth, reducing the impact forces experienced during re-entry.

“If we can reduce the g-loading on the sample canister colliding with the surface of Utah...the sample canister can get lighter and everything upstream gets easier and better.” - Ben Reed, Co-Founder and Chief Innovation Officer of Quantum Space

Reimagining the Entire MSR Architecture

Lockheed Martin, another company selected for the NASA study, is taking a broader approach by reassessing the entire MSR architecture.

Beau Bierhaus, principal research scientist at Lockheed Martin Space, outlined the company’s strategy to reduce complexity in the mission design. Past NASA flagship planetary missions typically involved no more than two elements, such as an orbiter and a lander, whereas the current MSR architecture includes up to nine interconnected components.

“Complexity doesn’t scale linearly by the number of elements,...Each of these things is co-dependent, co-mingled, and there are ripple effects between them, so the complexity scales non-linearly.” - Beau Bierhaus, Principal Research Scientist at Lockheed Martin Space

Lockheed Martin’s study will be guided by several principles, including a focus on key mission requirements, strict mass control, and a careful balance between performance and cost risks.

“We have an opportunity to look across the whole program and think about what heritage elements can be applied and where it makes sense to bring in new technology,” - Beau Bierhaus, Principal Research Scientist at Lockheed Martin Space

Boeing’s Alternative Vision

Although Boeing did not receive one of the NASA study contracts, the company has proposed a significant departure from the current MSR architecture.

Boeing Exploration Systems presented a concept that would involve a single large lander carrying a Mars Ascent Vehicle capable of launching samples directly back to Earth, bypassing the need for an Earth Return Orbiter. The Space Launch System (SLS) Block 2 rocket is ideally suited for this mission, as it could transport a 23-metric-ton lander with a high-performance liquid-propellant MAV.

“You eliminate a lot of complexity and you use available technology,” - Ben Donahue, Boeing Exploration Systems

Next Steps

The studies, which began in July 2024, are expected to be completed by October. NASA will review the findings alongside separate studies conducted by the Jet Propulsion Laboratory, Applied Physics Laboratory, and various NASA centers to determine which concepts could be incorporated into the MSR mission.

“The results of the studies will inform them what in the architecture could change, what needs to be done,” - Jim Green, Former NASA Chief Scientist

Despite the diverse range of approaches being explored, some experts have expressed concerns about the challenge of comparing and integrating these varied concepts. However, Northrop Grumman is collaborating with Lockheed Martin and the Jet Propulsion Laboratory to share insights on the MAV design, which could help harmonize the different studies.

“It’s a complicated problem,” - Jim Green, Former NASA Chief Scientist

The potential for innovation and improvement in the MSR mission remains high as NASA and its industry partners explore these new possibilities.