ALTEN Technology conducted comprehensive finite element analysis (FEA) and computational fluid dynamics (CFD) simulations on a family of XCOR upper-stage shuttle valves. The project focused on valves destined for a next-generation upper-stage LH2/LO2 spacecraft engine. Through detailed simulations, ALTEN Technology specified 2219-T98 aluminum for the valve body due to direct fuel exposure, and accurately determined pressure drop across the fuel valve assembly for both liquid hydrogen at 30 psia, 20 K, and gaseous hydrogen at 975 psia, 375 K. The team also determined yield and safety factors for the given loading conditions, making crucial design improvements to meet required safety factors and recommending further changes to decrease pressure drop. Solution-adaptive meshing was utilized to refine finite volume elements in high-gradient regions, ultimately increasing the client’s understanding of valve performance for future designs.