Engineering & Manufacturing Specialty Turbomachinery for Space Flight Applications
Barber-Nichols Inc. ( BNI ) has engineered, manufactured, and tested a wide range of equipment for numerous astronautic applications. BNI 's space flight hardware includes liquid rocket engine turbopumps, fuel densification systems, liquid fuel thruster pumps, and environmental control system pumps and fans. The space flight industry's strict design specifications, specialized material requirements, and conformance to high quality standards have provided an opportunity for Barber-Nichols' engineering team to hone its innovative skills.
BNI teamed with NASA's Marshall Space Flight Center (MSFC) to design and build the turbopump for the Fastrac LOX/RP-1 Engine, only the 
second space launch engine developed in the United States in the last 25 years. The Fastrac LOX/RP-1 Engine is part of NASA's Low Cost Technologies project and resulted in development of an engine that initially cost approximately $1.2 million - about 1/5 the cost of a similar engine.
Propellant Densification Systems
Most of today's largest rockets utilize Liquid Oxygen (LOX) and Liquid Hydrogen as engine propellants. Engineers at Rockwell Space Systems pioneered a simple idea for the densification of propellants which will revolutionize space travel. By lowering the temperatures of these fluids prior to transport to the launch vehicle's tanks, the volume required to store the propellants is reduced by approximately 7-15%. This substantially reduces tank size requirements and launch vehicle weight. With low earth orbit cost estimates at $10,000 per pound, this process results in substantial savings and the ability to launch greater payloads. Barber-Nichols designed and built the intricate series of pumps and compressors used on the first scaled down version of this innovative system. Originally tested at NASA's Lewis Plumbrook Field Station, results were positive. A full sized system was then designed and built for both Oxygen and Hydrogen and tested at NASA's Glenn Research Center.
Environmental Control Fans & Pumps
The Model BNP -12 Cabin Ventilation Fan was designed and manufactured for NASA's X-38 Crew Return Vehicle. The fan utilizes an in-line, hermetic, 
explosion proof design. It weighs 6.8 kg (15 lbs) and the flow rate is 560 m3 /hr (330 cfm). Additionally, BNI designed and manufactured a distilled water pump that was also used for environmental control on this vehicle. Barber-Nichols can design custom, or modify existing, fans and pumps to accommodate a wide variety of aeronautic and space flight applications including but not limited to electronic cooling, engine cooling, environmental control, and life support.
BNI designed and manufactured the Merlin Turbopump for Space Exploration Technologies' Falcon Launch Vehicle. Due to an innovative design, and the use of advanced materials, the Merlin Turbopump is extremely light weight, reliable, and inexpensive. The Merlin Engine has been tested to full power numerous times and the Falcon Launch Vehicle is scheduled for its maiden launch in spring 2007.
Barber-Nichols was recently awarded a NASA Phase II SBIR to design and manufacture two 204 m3/hr (900 gpm) liquid oxygen pumps. NASA currently uses one 273 m3/hr (1,200 gpm) pump to load the Space Shuttle's liquid oxygen propellant tank. The two new BNI pumps utilize improved, highly reliable shaft seals and are designed to be piped in parallel. The use of two pumps piped in parallel will increase the rate at which spacecraft are loaded to 408 m3/hr (1,800 gpm). The pumps are also controlled by variable frequency drives and should one pump go off line, the flow through the remaining pump can quickly be increased to 273 m3/hr (1,200 gpm). If confronted with a mechanical failure, this redundant pump system minimizes launch delays.