Bigelow Aerospace was an American space company that really shook things up with expandable habitat technology. Before shutting down in 2020, they notched some impressive milestones in commercial space from their Nevada base.
Robert Bigelow started Bigelow Aerospace in 1998. He wanted to build affordable space habitats that gave people more room than the usual cramped aluminum modules.
Bigelow used profits from his Budget Suites of America hotels to bankroll the company. That private money let them chase big ideas without waiting for government contracts.
They set out to make space accessible for all sorts of reasons—commercial research, private space stations, maybe even bases on the Moon someday.
Bigelow Aerospace called itself a destination company in the new commercial space world. They tried to attract customers who wanted lower-cost space habitation technology.
Robert Bigelow led the company from day one. Coming from hospitality, he brought a different mindset to space habitat design and how to treat customers.
He put about $250 million of his own money into the company. That’s a huge commitment and kind of shows how much he believed in the whole commercial space thing.
Bigelow’s ambitions didn’t stop at Earth orbit. He talked about lunar facilities and even deep space. He encouraged innovation and wasn’t afraid of taking risks to push new tech.
He stayed hands-on with the company until it closed in 2020. That direct involvement shaped Bigelow Aerospace’s direction and maybe even its culture.
Bigelow Aerospace set up shop in North Las Vegas, Nevada, back in 1999. Nevada gave them some business perks and easy access to aerospace testing grounds.
They built manufacturing and development facilities there, focused on making expandable habitat modules and the tech that goes with them.
North Las Vegas worked out pretty well for logistics, with good transport links. Plus, it was cheaper than California or Florida, which are the usual aerospace hotspots.
Inside those Nevada buildings, teams worked on new habitat designs. They tackled projects like the B330 spacecraft and other advanced expandable modules.
Bigelow Aerospace pulled off three big launches of expandable space structures starting in 2006. Genesis I and Genesis II proved the tech could actually work in orbit.
The real standout was the Bigelow Expandable Activity Module (BEAM), which they attached to the International Space Station. That module showed astronauts could safely use inflatable habitats.
NASA picked Bigelow for the NextSTEP program to help develop commercial space habitats. That partnership gave Bigelow some serious credibility.
Most of the company’s $250 million in funding came straight from Robert Bigelow. That cash fueled years of research and several space missions.
Bigelow Aerospace changed the game with inflatable module technology. Their approach slashed launch costs and gave astronauts way more room.
They started with NASA’s TransHab idea, but then added new materials and better radiation protection.
NASA came up with the TransHab inflatable module in the late ’90s for the International Space Station. The idea was to get more living space without taking up a ton of room during launch.
Congress killed the TransHab project in 2000 because of budget issues. Robert Bigelow saw an opportunity and bought the rights to the TransHab patents.
Bigelow’s team took those original NASA designs and made them way better. They worked on expandable modules that could work as space station parts or even as standalone habitats.
Genesis I and Genesis II, launched in 2006 and 2007, proved the inflatable tech could actually survive in space. Those early missions set the stage for bigger things.
Bigelow’s engineers built modules from several layers of flexible fabric, each layer spaced just right. The Bigelow Expandable Activity Module (BEAM) on the ISS is a great example of this technique.
These modules start small for launch, then expand once in space. BEAM, for instance, goes from about 2.16 meters long and 2.36 meters wide to 4.01 meters long and 3.23 meters wide after inflation.
Some quick specs:
Inflatable modules give you way more usable volume per kilogram than old-school metal ones. That means bigger living quarters and lower mission costs.
Bigelow’s inflatable modules use tough Kevlar-like fabrics and layers of closed-cell vinyl polymer foam. These materials shield crews from micrometeoroids and cosmic radiation.
NASA found that hydrogen-rich stuff like polyethylene blocks radiation better than aluminum. Bigelow’s multi-layer approach uses that idea in real-world habitats.
After a year in orbit, BEAM’s sensors showed radiation levels about the same as other ISS modules. The flexible materials held up well against cosmic rays and solar storms.
A Whipple shield approach protects against impacts. Multiple fabric layers absorb debris hits but keep the module airtight.
ATA Engineering took over BEAM’s technical support after Bigelow Aerospace stopped operating in 2021. NASA’s Johnson Space Center now runs the module.
The structure has two metal bulkheads joined by an aluminum frame. Around that, there are several fabric layers, plus an internal restraint and bladder system to keep the air in.
Materials include:
Sierra Nevada Corporation built the Common Berthing Mechanism, letting these modules dock with the ISS.
BEAM was supposed to last two years, but it’s still going strong as extra storage. Its success makes inflatable tech look pretty promising for future missions.
Bigelow Aerospace launched two important test flights to show their expandable modules could really work in space. Genesis I kicked things off in 2006, and Genesis II brought more upgrades in 2007.
Genesis I was Bigelow’s first real test for expandable habitat tech. They needed to prove inflatable modules could actually deploy in orbit.
On July 12, 2006, they launched Genesis I to test the basic engineering. The mission focused on whether the module could expand and hold up in space. Bigelow used it to show their design wasn’t just theory.
The module stretched 4.4 meters long and 2.54 meters wide when expanded. That’s about a third the size of their planned BA 330 habitat.
They packed Genesis I with cameras to watch the deployment. The spacecraft also tested out materials and structure in orbit. Their comms system was supposed to last six months, at least.
Bigelow couldn’t afford American launch prices, so they used a converted Russian ICBM called the Dnepr. The rocket took off from the Kosmotras Space and Missile Complex near Yasny, Russia.
Genesis II built on the first mission with more features and better sensors. It launched June 28, 2007, from the same Russian site.
This time, they added 22 cameras—way more than Genesis I. Ten new cameras gave them a better look inside and out. The new sensors tracked pressure, temperature, and radiation.
Genesis II also tested out attitude control in more detail. That gave Bigelow better data about how these modules behave in space.
The module was the same size as Genesis I but had beefed-up systems. Genesis II had 11.5 cubic meters of habitable volume, so they could run more thorough tests inside.
They ran the “Fly Your Stuff” program on Genesis II, letting customers pay $295 to send small items to orbit. The company took photos of each item floating in space.
Both Genesis missions outlasted their planned lifespans by a lot. Their communication systems kept working for over two years, even though they were only expected to last six months.
Genesis I and II proved that expandable habitats could work. The modules deployed as planned and stayed structurally sound. Their success built confidence in Bigelow’s engineering.
They even tried out some fun stuff, like space bingo games and an orbital billboard system using projectors. Genesis II displayed employee photos on its exterior.
Both modules are still up there, slowly losing altitude. Eventually, they’ll reenter Earth’s atmosphere and burn up.
The Genesis program gave Bigelow loads of data for bigger habitats. These missions paved the way for future crewed spacecraft and made expandable modules look like a real option for commercial space stations.
The Bigelow Expandable Activity Module was NASA’s first shot at testing inflatable habitat technology in orbit. Working with Bigelow Aerospace gave NASA a chance to see how these structures might change future space stations and deep space missions.
NASA teamed up with Bigelow Aerospace to build the first human-rated inflatable habitat for the space station. This partnership saved NASA a lot compared to building everything themselves.
They set up BEAM as a technology demo on the ISS. NASA managed the mission, while Bigelow handled design and manufacturing.
Key Partnership Details:
The goal was to get inflatable habitat tech ready for real missions. NASA could test commercial modules without spending a fortune on in-house development.
Johnson Space Center provided technical support and mission planning. The project showed how NASA and private companies could work together to move space habitat tech forward.
BEAM comes with a lightweight build that really stretches out once it’s in orbit. Astronauts get 565 cubic feet of space after the module, which weighs 3,115 pounds, fully expands.
When expanded, BEAM measures 13.2 feet long and 10.6 feet wide. It’s not huge, but it gives astronauts a spot for storage and some limited activities on the ISS.
BEAM Technical Specifications:
| Specification | Measurement |
|---|---|
| Mass | 3,115.1 lbs |
| Expanded Length | 13.2 feet |
| Expanded Diameter | 10.6 feet |
| Interior Volume | 565 cubic feet |
The expandable design cuts down on launch volume, making it way more efficient than rigid modules. BEAM packs up tight for launch, so spacecraft can carry more cargo.
Its walls shield astronauts from radiation, space debris, and other hazards. Several layers of special materials stand between the crew and things like micrometeorites or atomic oxygen.
SpaceX CRS-8 brought BEAM to the International Space Station on April 8, 2016. The Dragon spacecraft hauled the module up in its unpressurized trunk during that resupply run.
On April 16, 2016, the ISS crew used the Canadarm2 robotic arm to pull BEAM from Dragon’s trunk and install it onto the Tranquility module’s aft port. That part needed careful robotic moves to attach the module safely.
Mission Timeline:
It took over seven hours and 25 air bursts to inflate BEAM to full size. Engineers watched the process closely, checking the structure as it expanded.
Astronauts finally stepped inside on June 6, 2016, about two months after installation. NASA wanted to make sure everything worked and the module was safe before letting anyone in.
BEAM’s been running as a technology demo since 2016. NASA took over from Bigelow Aerospace in recent years, and now the module mostly serves as storage while still gathering data on how these habitats hold up.
The Bigelow Expandable Activity Module started out as an experiment when it arrived on the ISS in 2016. NASA filled it with sensors to keep tabs on its performance right from the start.
After a careful review in 2019, NASA gave BEAM the green light to keep operating through 2028. The module held up well—no big problems showed up during all that monitoring.
Early on, astronauts went inside BEAM regularly to inspect it and collect data. The module kept its environment stable and the structure solid, which is exactly what NASA wanted to see.
These days, BEAM mostly acts as long-term storage. The hatch connecting it to Node 3 usually stays closed, unless the crew needs to stash or retrieve something.
It holds supplies and gear that need a secure spot on the ISS. That extra storage helps free up space elsewhere while BEAM keeps sending back useful info.
NASA took full control of BEAM in December 2020, after Bigelow Aerospace’s contract ended. They brought in a new contractor to keep the inflatable module running.
With NASA in charge, the agency now handles all operations, maintenance, and planning for BEAM. The module pulls double duty as storage and as a long-term test bed for expandable habitat tech.
Engineering teams still monitor BEAM’s performance, hoping to learn more for future inflatable modules. Right now, storage is its main job—BEAM gives the ISS extra room for mission-critical supplies.
NASA expects to keep BEAM in service until at least 2028. That’s more time to collect data and support the next generation of commercial space habitats.
Bigelow Aerospace pushed inflatable habitat technology forward with its B330 modules, teaming up with several countries and space companies. The idea? Modular space stations that offer more living space than the old-school rigid modules.
The B330 module sat at the heart of Bigelow’s commercial station plans. Once expanded, each module gave crews 330 cubic meters of pressurized living space in orbit.
Inflatable modules like the B330 beat traditional habitats in several ways. One B330 could fit up to six people and weighed around 20,000 kg for launch. After expansion, it reached 6.7 meters across.
Bigelow built the B330 modules to work alone or link up into bigger complexes. Each one came with life support, docking ports, and radiation shielding. The company wanted to launch them on Atlas V rockets or the new Vulcan rockets.
Key B330 Specifications:
Bigelow signed on seven nations to use its commercial stations: the UK, Netherlands, Australia, Singapore, Japan, Sweden, and the UAE.
They worked with SpaceX and Boeing for crew rides. SpaceX would use Dragon capsules on Falcon 9 rockets, while Boeing offered Starliner capsules on Atlas V. Seats cost $26.5 million with SpaceX, $36.75 million with Boeing.
NASA gave Bigelow a $17.8 million contract for BEAM, which attached to the ISS in 2016 and proved inflatable habitats could work. BEAM still operates today, storing cargo and sending back data.
United Launch Alliance agreed to launch B330 modules on Atlas V, and later looked to the Vulcan rocket for bigger missions.
Bigelow’s modular approach meant flexible station setups. Their Space Complex Alpha concept put two B330s together, creating 690 cubic meters of pressurized space.
Each B330 included docking systems that worked with both Russian and NASA ports. That made it easy to connect modules or dock visiting spacecraft from different countries.
The design fit a bunch of missions. One B330 could run as a standalone station, or you could link several to the ISS or each other for research, manufacturing, or even tourism.
Leasing a third of a B330 for two months cost $25 million. Bigelow figured a full station would need 24 launches a year for crew and cargo, supporting up to 12 people across connected modules.
Inflatable tech allowed much more space per launch compared to rigid structures. Rocket fairings limit traditional modules, but expandable habitats squeeze in small and grow big in orbit.
Bigelow Aerospace built its business on smart partnerships with launch providers and by keeping an eye on rivals in the growing commercial station market. Their work with United Launch Alliance (ULA) brought essential launch options, while competitors like Axiom Space kept things interesting.
Bigelow teamed up with ULA in April 2016 to send habitable modules into Low Earth orbit. They aimed to launch the B330 expandable module using ULA’s Atlas V 552 rocket.
The B330 gave researchers 330 cubic meters of zero-gravity space for science and manufacturing. Bigelow planned to attach it to the ISS under the project name XBASE (Expandable Bigelow Advanced Station Enhancement).
Adding a B330 would boost ISS volume by about 30 percent. NASA’s commercial crew providers would handle astronaut rides to the module.
ULA brought reliability and good pricing for these heavy modules. Together, the companies worked on business plans and marketing for future B330 missions, even looking at lunar and Mars destinations.
Several companies want to build the next big space station. Axiom Space, Bigelow, and NanoRacks all have their own module plans for future orbital outposts.
Bigelow also joined forces with SpaceX to market rides for international customers. SpaceX would fly passengers to Bigelow habitats in orbit using Dragon and Falcon rockets.
On top of that, Bigelow made deals with six U.S. states to use future stations. Their operations arm, Bigelow Space Operations, teamed up with the Center for the Advancement of Science in Space to send payloads to the ISS.
These partnerships gave Bigelow a solid spot in the commercial habitat race. Each company brought its own strengths and customer focus to the table.
NASA’s changing space policy really shaped Bigelow’s opportunities. The agency pivoted from Low Earth Orbit partnerships to deep space projects like Gateway lunar station.
Bigelow had to rethink its business as NASA’s priorities shifted. The company adjusted its customer approach and project planning.
Federal policy also set the rules for commercial space habitats. Bigelow operated under FAA regulations while chasing NASA contracts for research and station extensions.
The commercial crew program helped, too. More crew providers meant more ways to reach Bigelow’s modules, whether attached to the ISS or flying solo.
Bigelow Aerospace carved out a big role in the commercial space economy by betting on expandable habitats and private stations. Their business model focused on leasing modules to governments and private clients, helping shape commercial spaceflight as a whole.
Bigelow built its business around leasing expandable habitats instead of selling them. That way, customers could use space stations without massive upfront costs.
They set up Bigelow Space Operations (BSO) to handle sales, daily operations, and customer support. This let Bigelow Aerospace focus on manufacturing while BSO looked after clients.
Robert Bigelow and his team aimed at government agencies first but also chased commercial space stations for private research and manufacturing.
The B330 series was the main product. Each module came with over 330 cubic meters of usable space. Just one B330 could offer 2.4 times the pressurized volume of the whole ISS.
Bigelow’s pricing aimed to beat government-built options. They pitched their modules as affordable, practical solutions for anyone needing dedicated space.
Bigelow helped prove that private companies can build space infrastructure without depending on government programs. The BEAM module’s success on the ISS showed that inflatable habitats really do work in orbit.
Their approach shaped NASA’s own commercial space plans. NASA had developed early technology under the TransHab program, which Bigelow licensed and took further. That partnership became a sort of playbook for other commercial space projects.
Bigelow pushed for light-touch regulations to keep private investment flowing. Robert Bigelow even spoke to Congress about the need for rules that wouldn’t slow down commercial space work.
They also promoted the idea of space manufacturing and saw the Moon as a near-future goal for mining and resource extraction.
Bigelow’s expandable habitats brought some real perks to space manufacturing. With so much room inside, you could fit all sorts of industrial gear and set up production lines that actually need space to breathe.
The company saw the Moon as a sweet spot for commercial manufacturing. Unlike asteroids or Mars, lunar operations could get off the ground sooner using tech we already have.
Bigelow’s habitat design let manufacturers bring in equipment for making goods in zero or low gravity. The built-in atmosphere and temperature controls would keep delicate processes running smoothly.
Manufacturers could tweak these modular habitats for whatever they wanted to produce. If things took off, they could just connect more B330 modules and build out bigger complexes.
Commercial space stations based on Bigelow tech could act as a testbed for lunar manufacturing. Companies could try out their ideas in low Earth orbit first, before risking it all farther from home.
Bigelow Aerospace once dreamed big—from space hotels in orbit to lunar depots. But tough realities forced them to hit pause on most projects. Their expandable habitat system looked promising, especially after BEAM’s success, but the larger vision never quite materialized.
Bigelow built its business plan around launching the first commercial space hotel with expandable habitats. The idea was to send up larger versions of BEAM and create orbital stays for paying customers.
Robert Bigelow pictured stations where tourists, scientists, and businesses could spend time in orbit. Everything would use that same inflatable tech already tested on the ISS.
The hotel plan needed several launches to build out a full station. Each module would offer more room than old-school rigid designs and still save weight on launch.
Bigelow aimed to build places where people could actually live and work in space, not just pass through. The expandable approach made long-term stays more comfortable than cramped capsules ever could.
Bigelow announced they’d launch a lunar depot by 2022, pushing past Earth orbit. This habitat would circle the Moon and help support surface missions.
They saw lunar work as the next logical step after low Earth orbit. The same inflatable tech could give astronauts a place to live and work on their way to and from the Moon.
Operating a lunar depot came with big technical hurdles. The habitat had to survive deep space radiation and keep crews safe for long stretches, far from home.
These ambitions lined up with NASA’s bigger plans for lunar exploration and commercial partnerships. Bigelow wanted a seat at the table for those missions.
Bigelow Aerospace went quiet, with no big projects on the horizon. Financial strain and a tough market kept them from finishing their commercial station ideas.
COVID-19 hit hard, throwing off their timelines and funding. Before that, Bigelow looked ready to start building private stations in low Earth orbit.
Competition ramped up as companies like SpaceX and Axiom Space jumped into the commercial station race. Suddenly, Bigelow wasn’t the only game in town.
Technical problems slowed things down after BEAM’s success. Scaling up from small tests to full-blown stations needed more money and time than Bigelow could pull together.
Bigelow Aerospace worked closely with NASA and research groups, and they always seemed to get plenty of attention from space media. Their expandable habitat tech caught the eye of journalists and opened doors for students and scientists in different fields.
Bigelow teamed up with NASA for projects like the Bigelow Expandable Activity Module (BEAM). This let researchers run microgravity experiments on the ISS using Bigelow’s inflatable modules.
BEAM gave NASA a way to test expandable structures in real space conditions. NASA’s Advanced Exploration Systems Division helped out, and the project produced valuable data on how these habitats hold up over time.
Universities got to propose experiments for these modules, pushing research in materials science and space living.
Scientists used the steady environment inside these habitats for experiments that needed low vibration and tight controls.
Bigelow also worked with the Center for the Advancement of Science in Space (CASIS). This partnership helped researchers get their gear to the ISS, broadening what scientists could do in orbit.
SpaceNews kept a close eye on Bigelow’s progress and business moves. They covered the company from early ideas to real-world testing.
Aerospace journalist Jeff Foust reported on Bigelow’s plans for commercial stations and new partnerships. He often analyzed their business model and where they fit in the market.
Industry media talked up Bigelow’s work with SpaceX on international marketing. There were reports on meetings with Japanese officials and plans to offer commercial station services.
The launch of Bigelow Space Operations got a lot of buzz. News outlets covered the shift from building modules to running commercial operations and serving customers.
Journalists discussed Bigelow’s role in making space stations more private and less expensive. They wondered if this approach could open up low Earth orbit to more players.
Bigelow’s technology made its way into aerospace engineering classes across the country. Students studied inflatable habitats as a real alternative to old-school rigid modules.
Their partnership model showed how private companies could work with government agencies. It’s now a go-to example for public-private teamwork in aerospace education.
Places like MIT included Bigelow’s expandable concepts in their courses. Students dug into the mechanics and materials science behind these inflatable structures.
The company’s work set new standards for commercial station design. Other aerospace firms have started using similar ideas for their own habitats.
By winning NASA contracts, Bigelow gave students concrete examples of how engineering theory becomes reality. Testing these modules in space made the lessons stick.
Bigelow Aerospace really shook up space habitat tech with their inflatable module designs. They proved that expandable structures could work for commercial space stations and set the stage for next-generation orbital facilities.
Bigelow changed the game by perfecting inflatable modules that NASA had once shelved in the ’60s. They picked up NASA’s TransHab tech in 2004 and turned it into something real and usable.
Genesis I and II missions showed that expandable modules could survive in orbit. Bigelow launched these prototypes on converted Russian rockets, and both deployed and pressurized successfully.
The Bigelow Expandable Activity Module (BEAM) stands out as their biggest win. SpaceX delivered BEAM to the ISS in 2016, where it expanded from a compact 7.1 feet to a roomy 13.2 feet long and 10.6 feet wide.
BEAM offers 565 cubic feet of pressurized space and still operates on the ISS today.
Bigelow designed bigger habitats too, like the BA330 with 12,000 cubic feet inside. That’s three times more than the ISS Destiny module, and it still fit inside a rocket fairing.
Today’s commercial station builders have run with Bigelow’s expandable ideas. They’re using inflatable modules to get more room for less launch mass.
Sierra Space uses expandable modules for its planned stations. Their LIFE habitat relies on the same inflation tricks Bigelow proved out with BEAM.
Axiom Space adds expandable elements to stations for the Moon and Mars. They’re following Bigelow’s original vision for deep space exploration.
NASA’s commercial station program benefits from Bigelow’s work, too. They use BEAM’s data to check inflatable habitats for future missions beyond low Earth orbit.
Space agencies everywhere now see expandable modules as key for Mars trips. Bigelow showed that you can pack a big living space into a standard rocket.
Bigelow Aerospace gets a lot of questions about where things stand, who’s steering the ship, and what makes them unique. Their work covers commercial space habitats, private space exploration, and even some unexpected research.
Bigelow Aerospace halted most operations in March 2020, laying off its team because of money issues and the COVID-19 pandemic. They’d been working on inflatable habitats for commercial use in low Earth orbit.
Before shutting things down, Bigelow launched two test modules to the ISS. The BEAM (Bigelow Expandable Activity Module) still sits attached to the station, giving NASA important data on expandable habitats.
Their North Las Vegas site is mostly quiet these days. Robert Bigelow hasn’t shared any plans to bring operations back.
Robert Bigelow founded the company in 1999 and kept it focused on inflatable space habitats. He wanted to build affordable commercial stations using NASA-licensed tech.
His personal interests steered some company priorities. He put a lot of money into UFO research through Bigelow Aerospace Advanced Space Studies (BAASS).
Bigelow preferred to move fast, skipping the usual aerospace pace. That helped them build prototypes quickly, but it also caused funding headaches when customers didn’t show up.
Bigelow pushed inflatable habitat tech forward with real-world ISS tests. BEAM proved that you could trust an expandable module to house astronauts in space.
They launched Genesis I and II in 2006 and 2007—both were free-flying prototypes that tested these systems before anyone else tried it.
Bigelow also designed the B330 commercial station, which would have offered 330 cubic meters of space and supported up to six crew members for long missions.
Bigelow Aerospace is a private company—there’s no stock to buy. Robert Bigelow owns and funds it himself.
They haven’t opened up to public investment or outside funding rounds. While most space startups look for investors, Bigelow has kept things in-house.
So, you can’t grab shares on the stock market or through private placements. They’d need to change their ownership structure before that could happen.
Bigelow Aerospace Advanced Space Studies worked with the Pentagon’s Advanced Aerospace Threat Identification Program from 2008 to 2012. They investigated UFO reports for the Defense Intelligence Agency.
The company gathered and studied reports from both military and civilian sources. BAASS kept databases and even did field investigations.
Robert Bigelow has said publicly that he believes extraterrestrials have visited Earth. He’s funded UFO research separately from the company’s habitat work.
Bigelow Aerospace really took off thanks to NASA’s commercial space programs in the 2000s and 2010s. NASA pushed for more public-private partnerships, and that opened doors for Bigelow’s expandable habitat tech.
But then NASA started caring more about lunar exploration. That pivot meant less focus on commercial low Earth orbit stations, so Bigelow suddenly faced a shrinking market for its space habitats.
The Pentagon handed Bigelow some UFO research contracts, which brought in fresh revenue. Still, those contracts also drew a lot of attention—sometimes the kind that makes traditional aerospace work a bit trickier.
