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USSRC Pathfinder Shuttle

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LOCATION: Huntsville, AL
COLLABORATORS: U.S. Space & Rocket Center
FABRICATOR: Branch Technology

PROJECT DESCRIPTION: Originally built in 1977 to test critical aspects of the Space Transportation System, the 121-foot-long Pathfinder Shuttle was in desperate need for restoration. In search of a lightweight material, the U.S. Space & Rocket Center (USSRC) turned to Branch Technology to restore the exterior with the goal of replicating the orbiter at its original size. Branch 3D-printed 516 panels, which were attached to the original airframe. The fully restored Pathfinder now weighs 220,000 pounds, with Branch CompositeCore® contributing only around 40,000 pounds. While preserving as many historic components as possible—including two of the three original engine bells—the Pathfinder was reassembled and returned to its permanent display at the U.S. Space & Rocket Center Museum in September 2024.
This marks Branch Technology’s third collaboration with the Center, showcasing the use of innovative 3D design into the world of space. Other projects include BranchClad® panels for the gorgeous lunar facades on the Boeing Space Camp Operations Center and BranchClad® Interior “Nebula Panels” inspired by the swirling storms of Jupiter.