The Environmental Test Laboratory, built in the 1960s and upgraded since, has hosted testing for missions ranging from NASA's Ranger lunar spacecraft to the Perseverance Mars rover and the Europa Clipper mission now on its way to Jupiter. At JPL the lab team uses these chambers and shakers to reproduce the jolts, rattling, and extreme sound levels that spacecraft experience during ascent and in space.

That history and the lab's accumulated experience now extend to industry partners flying under NASA's Commercial Lunar Payload Services initiative within the Artemis campaign to return astronauts to the Moon. A structural qualification unit representing Firefly's uncrewed Blue Ghost Mission 2 configuration was recently exercised in the lab's vibration and acoustic facilities to refine design margins and test plans for the flight vehicle, which is slated to launch as early as 2026.

"There's a lot of knowledge gained over the years, passed from one generation of JPL engineers to another, that we bring to bear to support our own missions as well as commercial efforts," said Michel William, a JPL engineer in the Environmental Test Laboratory who led the testing. "The little details that go into getting these tests right - nobody teaches you that in school, and it's such a critical piece of space launch."

Blue Ghost Mission 2 uses a dual-spacecraft layout with Firefly's Elytra Dark orbital vehicle mounted beneath the Blue Ghost lunar lander. Standing 22 feet, or 6.9 meters, high, the assembled structure is more than three times as tall as the company's Mission 1 lander, which also underwent environmental testing at JPL before its lunar soft landing in March 2025. The Mission 2 stack will carry multiple NASA and international payloads to the Moon's far side.

In the fall campaign the qualification stack was bolted to a shaker table inside a JPL clean room and driven along three axes while hundreds of sensors tracked how the hardware moved. Engineers then shifted the vehicle into an acoustic chamber, where horns built into 16-inch-thick, or 41-centimeter-thick, concrete walls used compressed nitrogen gas to generate sound levels up to 153 decibels, comparable to the launch noise environment that can cause permanent hearing damage in humans.

Each test sequence included multiple runs at rising intensity. Between runs, JPL dynamics specialists reviewed the measurements against computer simulations to check how closely the results matched expectations. When the data diverged from models, the team either adjusted the hardware configuration or updated the models to better capture the spacecraft response, working to avoid both insufficient and excessive test conditions.

"You can either under-test or over-test, and both are bad," William said. "If you over-test, you can break your hardware. If you under-test, it can break on the rocket. It's a fine line."

Because the structural qualification unit will not launch, Firefly's visit to JPL did not include some activities reserved for flight hardware. Spacecraft headed to the pad undergo electromagnetic testing to confirm that their electronics do not interfere with one another, and they are also cycled through high and low temperatures inside thermal vacuum chambers that remove air to simulate the vacuum of space. JPL's facilities include several such chambers, among them historic space simulators about 10 feet and 25 feet in diameter that date to NASA's early years.

Completion of the Environmental Test Laboratory campaign on the structural qualification model helps show that Firefly's design can withstand ascent on a SpaceX Falcon 9 rocket. With this step done, the Blue Ghost Mission 2 team is focusing on assembly and testing of the flight spacecraft that will travel to the Moon.

After arrival in lunar orbit, the Blue Ghost lander is planned to touch down on the far side and deliver its payloads to the surface. The manifest includes LuSEE-Night, a low-frequency radio telescope developed by NASA, the U.S. Department of Energy, and the University of California, Berkeley's Space Sciences Laboratory to conduct observations from the radio-quiet lunar night side.

The mission will also fly a JPL-developed payload called User Terminal to demonstrate a compact, low-cost S-band radio system. The test aims to show how small communications packages could support links between far-side surface assets and relay orbiters on future robotic and crewed missions.

Meanwhile Firefly's Elytra Dark orbital vehicle will deploy ESA's Lunar Pathfinder communications satellite into lunar orbit, a mission on which NASA is collaborating by supplying mirrors to enhance navigation capabilities. Both the lander and Elytra Dark are expected to maintain relay services that can return data from the far side to Earth after landing.

"Firefly's Blue Ghost Mission 2 will deliver both NASA and international commercial payloads to further prove out technologies for Artemis and help enable a long-term presence on the Moon," said Ray Allensworth, Firefly's spacecraft program director. "The extensive spacecraft environmental testing we did at JPL for Mission 1 was a critical step in Firefly's test campaign for our historic lunar mission. Now we're collaborating again to support a successful repeat on the Moon that will unlock even more insights for future robotic and human missions."

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