Reusable rockets must rely on well-designed Guidance, Navigation and Control (GNC) algorithms. Because they are tested and verified in closed-loop, high-fidelity simulators, emphasizing the strategy to achieve such advanced models is of paramount importance. A wide spectrum of complex dynamic behaviors and their cross-couplings must be captured to achieve sufficiently representative simulations, hence a better assessment of the GNC performance and robustness. This paper focuses on of the main aspects related to the physical (acausal) modeling of reusable rockets, and the integration of these models into a suitable simulation framework oriented towards GNC Validation and Verification (V&V). Firstly, the modeling challenges and the need for physical multibody models are explained. Then, the Vertical Landing Vehicles Library (VLVLib), a Modelica-based library for the physical modeling and simulation of reusable rocket dynamics, is introduced. The VLVLib is built on specific principles that enable quick adaptations to vehicle changes and the introduction of new features during the design process, thereby enhancing project efficiency and reducing costs. Throughout the paper, we explain how these features allow for the rapid development of complex vehicle simulation models by adjusting the selected dynamic effects or changing their fidelity levels. Since the GNC algorithms are normally tested in Simulink^®, we show how simulation models with a desired fidelity level can be developed, embedded and simulated within the Simulink^® environment. Secondly, this work details the modeling aspects of four relevant vehicle dynamics: propellant sloshing, Thrust Vector Control (TVC), landing legs deployment and touchdown. The CALLISTO reusable rocket is taken as study case: representative simulation results are shown and analyzed to highlight the impact of the higher-fidelity models in comparison with a rigid-body model assumption.

Prior to landing of reusable space transportation systems, the vehicle’s landing legs needs to be fully deployed to enable a safe landing and further re-use of the space vehicle. During that phase the deployment system has to overcome harsh and challenging environmental conditions. In this study, a numerical simulator is developed in order to investigate these influences on the landing leg deployment dynamics. By means of an extensive aerodynamic database and a broad approach flight domain, the influence of aerodynamics, exhaust plume, and vehicle’s attitude on the deployment dynamics is analyzed. This study shows on the example of the first stage demonstrator CALLISTO (Cooperative Action Leading to Launcher Innovation in Stage Toss back Operations), that thrust level, vehicle attitude, and the deployment system parameters affect the deployment performance.

CALLISTO is a collaborative project between JAXA, CNES, and DLR, focused on developing and operating a scaled reusable vertical-takeoff vertical-landing rocket stage demonstrator. This initiative is a crucial step for advancing reusable launch vehicle (RLV) technology in Europe and Japan. Significant strides have been made during the recently completed phase C of the project, particularly in aerodynamic modeling, guidance, navigation, and control design, landing dynamics, and flight domain definitions. These advancements facilitate the development of future operational vehicles and provide insights applicable to other RLV projects. This paper provides an update on the design and development status of the CALLISTO vehicle. It outlines the program objectives, focusing on mission design, vehicle life cycle, and their distinctions from legacy expendable launch vehicles in Europe and Japan. Details of the flight test plan, including in-flight experimentation, are elucidated, demonstrating incremental progress toward acquiring key technology and preparing for high-energy missions. Furthermore, the paper offers an overview of the CALLISTO vehicle’s development status, highlighting key architectural features such as load-carrying structures, avionics, rocket propulsion system, flight control systems, and approach and landing system. It underscores the milestones achieved over the past years and the progress toward the first flights. With a flight test campaign to be performed at Europe’s Spaceport in French Guiana, the CALLISTO project signifies a crucial step toward enhancing launch system affordability, competitiveness, versatility, and sustainability. This collaboration among three space organizations highlights the importance of shared expertise in advancing RLV technology and preparing for the next generation of launch vehicles.

Small penetrator probes have been proposed regularly as low(er) cost landing elements, particularly for network science. This study reviews such a concept with regard to its soil penetration capability with numerical and experimental investigations. A reference micro Mars lander (MML) is considered to deliver a 10 kg payload to the Martian surface. It decelerates the penetrator probe with a mechanical decelerator to 40–60 m/s before impact. The remaining kinetic energy is distributed to the soil and an internal load limiter on impact, which restricts the maximum g-load acting on the payload. A semi-empirical force–displacement law and a discrete element method simulation were used to describe penetration behavior. Major impact force constituents are the velocity-dependent, drag-like displacement of the soil particles and the compaction of soil along the penetration path. Based on the simulation results, a test penetrator was designed and tested by impacting it on different soil conditions with a maximum impact velocity of 10 m/s. Cohesive Mars soil simulant, non-cohesive quartz sand, and stones of various sizes were used to assess different impact conditions. The comparison of test and simulation data identifies their respective capabilities and limitations. Recommendations for use and findings for further research are deduced therefrom.

Small penetrator probes have been proposed regularly as low(er) cost landing elements particularly for network science. This study reviews such a concept with regard to its soil penetration capability with numerical and experimental investigations. A reference Micro Mars Lander (MML) is considered to deliver a 10 kg payload to the Martian surface. It decelerates the penetrator probe with a mechanical decelerator to 40–60 m/s before impact. The remaining kinetic energy is distributed to the soil and an internal load limiter on impact, which restricts the maximum g-load acting on the payload. A semi-empirical force-displacement law and a discrete element method simulation were used to describe penetration behavior. Major impact force constituents are the velocity-dependent, drag-like displacement of the soil particles and the compaction of soil along the penetration path. Based on the simulation results, a test penetrator was designed and tested by impacting it on different soil conditions with a maximum impact velocity of 10 m/s. Cohesive Mars soil simulant, non-cohesive quartz sand, and stones of various sizes were used to assess different impact conditions. The comparison of test and simulation data identifies their respective capabilities and limitations. Recommendations for use and findings for further research are deduced therefrom.