Starlab Selects Vivace to Manufacture Primary Structure for Commercial Space Station

Rhea-AI Summary

Starlab Space LLC has chosen Vivace Corporation to manufacture the primary structure of its next-generation commercial space station. The aluminum-based structure, among the largest single spaceflight structures ever developed, will be built at Vivace's New Orleans facility with support from the Michoud Assembly Facility (MAF).

The project aims to extend the International Space Station's legacy by providing continuous access to low-Earth orbit for scientific research, technology development, and commercial applications. As NASA's most capable Commercial LEO Destination (CLD) concept, Starlab will support a continuous astronaut presence and serve various national and international users. The station's development is progressing toward its Critical Design Review in December, with launch planned for later this decade.

Positive

• Selection of established manufacturer Vivace brings expertise in large-scale aerospace manufacturing
• Project leverages existing infrastructure at Michoud Assembly Facility (MAF) for specialized manufacturing
• Starlab positioned as most capable of NASA's Commercial LEO Destination concepts
• Development progressing towards Critical Design Review milestone in December

Negative

• Complex manufacturing process of one of the largest space structures in history presents technical challenges
• Launch timeline extends to 'later this decade' indicating significant wait before operational status

Insights

Aerospace Engineering Expert

Starlab's selection of Vivace to build its space station's primary structure marks a significant industrial partnership advancing NASA's commercial LEO strategy.

This partnership between Starlab Space LLC and Vivace Corporation represents a significant industrial milestone in the development of commercial space infrastructure. The agreement tasks Vivace with manufacturing what will be one of the largest single spaceflight structures ever developed for launch - the aluminum-based primary structure for Starlab's commercial space station.

Starlab is positioned as NASA's most capable Commercial LEO Destination (CLD) concept, designed to provide continuity after the International Space Station's retirement. The selection of Vivace leverages their advanced aerospace engineering capabilities alongside specialized facilities at the Michoud Assembly Facility (MAF) in Louisiana - a facility with historical significance dating back to WWII that now serves as a multi-tenant aerospace manufacturing hub.

From an engineering perspective, this represents a complex manufacturing challenge requiring precision engineering for a structure that must withstand launch forces while maintaining integrity for long-duration spaceflight. The project will utilize Vivace's high-Technology Readiness Level (TRL) capabilities, indicating mature, flight-proven engineering approaches rather than experimental technologies.

The timing of this announcement is significant as it precedes Starlab's Critical Design Review scheduled for December - a crucial engineering milestone where the detailed design is evaluated before proceeding to full-scale manufacturing. With development of the flight article already underway and launch planned for later this decade, this manufacturing partnership represents a concrete step toward establishing persistent commercial capabilities in low-Earth orbit following the eventual decommissioning of the ISS.

This agreement marks a major milestone in the development of Starlab and another step toward its Critical Design Review in December.

HOUSTON and NEW ORLEANS, Sept. 24, 2025 /PRNewswire/ -- Starlab Space LLC has selected Vivace Corporation to manufacture the primary structure for its next-generation commercial space station. The aluminum-based structure, one of the largest single spaceflight structures ever developed for launch, will be built at Vivace's facility in New Orleans, La., with additional development and testing support from the Michoud Assembly Facility (MAF) in Louisiana.

Starlab is designed to extend the legacy of the International Space Station and provide uninterrupted access to low-Earth orbit for scientific research, technology development and commercial applications. As the most capable of NASA's Commercial LEO Destination (CLD) concepts, Starlab will offer a continuous astronaut presence and support a wide range of national and international users.

"Selecting Vivace to lead the manufacturing of Starlab's primary structure is a major milestone," said Marshall Smith, Starlab CEO. "Starlab is meticulously engineered to deliver scalability, reliability, and mission-critical research to our partners. This collaboration is instrumental in transforming that vision into reality, perpetuating the ISS legacy, and ensuring NASA and its international partners continue to have seamless access to orbit in the post-ISS era."

Vivace will leverage its advanced aerospace engineering expertise, collaborating with Starlab and its international partners, to finalize the design-to-manufacture and begin the manufacturing process for the primary structure.

"Vivace is honored to be selected as Starlab's partner for this groundbreaking program," said Steve Cook, Chairman of Vivace. "Manufacturing one of the largest space structures in our nation's history demands precision, expertise, and proven processes. Leveraging Vivace's high-TRL capabilities and facilities in Louisiana, we are proud to contribute to this significant project supporting U.S. and allied leadership in human spaceflight."

The program will use Vivace's New Orleans facility at MAF for fabrication, with support from U.S. Government partners for subject matter expertise, structural analysis and potential test infrastructure. MAF will also support specialized large-scale manufacturing and assembly operations.

Louisiana Governor Jeff Landry added, "We are excited that Vivace Corporation and Starlab have partnered to utilize the NASA Michoud Assembly Facility as a central element in the design and build of the structures for the Starlab spacecraft. Our human spaceflight program is essential to U.S. national security, and leveraging this world-class multi-tenant facility, which originally played a role in winning WWII, is a key part of 'Freedom's Forge 2.0'."

Development is underway on the station's flight article, with a rigorous testing campaign ahead of its historic launch later this decade. Once operational, Starlab will deliver sustained, unmatched research and commercial opportunities in microgravity, supporting life sciences, advanced materials and technology demonstrations for government and private sector customers.

About Starlab

Starlab Space is a U.S.-led, global joint venture among Voyager Technologies (NYSE: VOYG), Airbus, Mitsubishi Corporation, MDA Space and Palantir Technologies, with strategic partners including Hilton, Northrop Grumman and The Ohio State University. Starlab is developing a next-generation, AI-enabled commercial space station, aiming to ensure continued human presence in low-Earth orbit and a seamless transition of microgravity science and research alongside the retirement of the International Space Station. Starlab's advanced, user-driven design and robust capabilities make it a premier platform for scientific discovery and technological advancement in space. For more information, visit starlab-space.com.

About Vivace International
Founded in 2006 and based in NASA's Michoud Assembly Facility near New Orleans, Louisiana, Vivace provides mission-critical product development, engineering, and management services for U.S. spaceflight systems, hypersonics, and launch vehicle markets. Its products include flight hardware, ground support equipment, development hardware, tooling, and engineering services. From concept development through detailed design, analysis, manufacture, and test, Vivace develops high-performance, efficient solutions and delivers them on time. Learn more at Vivace.com.

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SOURCE Starlab

FAQ

What is Starlab's partnership with Vivace Corporation for the commercial space station?

Vivace Corporation has been selected to manufacture Starlab's primary aluminum-based structure, one of the largest single spaceflight structures ever developed, at their New Orleans facility with support from the Michoud Assembly Facility.

When will the Starlab space station be operational?

The space station is scheduled for launch later this decade, following completion of development and a rigorous testing campaign.

What is the purpose of the Starlab commercial space station?

Starlab will extend the ISS legacy by providing continuous access to low-Earth orbit for scientific research, technology development, and commercial applications, supporting both government and private sector customers.

Where will the Starlab space station structure be manufactured?

The primary structure will be manufactured at Vivace's facility in New Orleans, Louisiana, with additional development and testing support from the Michoud Assembly Facility (MAF).

What is the next major milestone for Starlab's development?

Starlab's next major milestone is its Critical Design Review scheduled for December.