Kennedy Space Center

Rivals object to SpaceX’s Starship plans in Florida—who’s interfering with whom?

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“We’re going to continue to treat any LOX-methane vehicle with 100 percent TNT blast equivalency.”

Artist’s illustration of Starships stacked on two launch pads at the Space Force’s Space Launch Complex 37 at Cape Canaveral, Florida. Credit: SpaceX

The commander of the military unit responsible for running the Cape Canaveral spaceport in Florida expects SpaceX to begin launching Starship rockets there next year.

Launch companies with facilities near SpaceX’s Starship pads are not pleased. SpaceX’s two chief rivals, Blue Origin and United Launch Alliance, complained last year that SpaceX’s proposal of launching as many as 120 Starships per year from Florida’s Space Coast could force them to routinely clear personnel from their launch pads for safety reasons.

This isn’t the first time Blue Origin and ULA have tried to throw up roadblocks in front of SpaceX. The companies sought to prevent NASA from leasing a disused launch pad to SpaceX in 2013, but they lost the fight.

Col. Brian Chatman, commander of a Space Force unit called Space Launch Delta 45, confirmed to reporters on Friday that Starship launches will sometimes restrict SpaceX’s neighbors from accessing their launch pads—at least in the beginning. Space Launch Delta 45, formerly known as the 45th Space Wing, operates the Eastern Range, which oversees launch safety from Cape Canaveral Space Force Station and NASA’s nearby Kennedy Space Center.

Chatman’s unit is responsible for ensuring all personnel remain outside of danger areas during testing and launch operations. The range’s responsibility extends to public safety outside the gates of the spaceport.

“There is no better time to be here on the Space Coast than where we are at today,” Chatman said. “We are breaking records on the launch manifest. We are getting capability on orbit that is essential to national security, and we’re doing that at a time of strategic challenge.”

SpaceX is well along in constructing a Starship launch site on NASA property at Kennedy Space Center within the confines of Launch Complex-39A, where SpaceX also launches its workhorse Falcon 9 rocket. The company wants to build another Starship launch site on Space Force property a few miles to the south.

“Early to mid-next year is when we anticipate Starship coming out here to be able to launch,” Chatman said. “We’ll have the range ready to support at that time.”

Enter the Goliath

Starship and its Super Heavy booster combine to form the largest rocket ever built. Its newest version stands more than 400 feet (120 meters) tall with more than 11 million pounds (5,000 metric tons) of combustible methane and liquid oxygen propellants. That will be replaced by a taller rocket, perhaps as soon as 2027, with about 20 percent more propellant onboard.

While there’s also risk with Starships and Super Heavy boosters returning to Cape Canaveral from space, safety officials worry about what would happen if a Starship and Super Heavy booster detonated with their propellant tanks full. The concern is the same for all rockets, which is why officials evacuate predetermined keep-out zones around launch pads that are fueled up for flight.

But the keep-out zones around SpaceX’s Starship launch pads will extend farther than those around the other launch sites at Cape Canaveral. First, Starship is simply much bigger and uses more propellant than any other rocket. Secondly, Starship’s engines consume methane fuel in combination with liquid oxygen, a blend commonly known as LOX/methane or methalox.

And finally, Starship lacks the track record of older rockets like the Falcon 9, adding a degree of conservatism to the Space Force’s risk calculations. Other launch pads will inevitably fall within the footprint of Starship’s range safety keep-out zones, also known as blast danger areas, or BDAs.

SpaceX’s Starship and Super Heavy booster lift off from Starbase, Texas, in March 2025. Credit: SpaceX

The danger area will be larger for an actual launch, but workers will still need to clear areas closer to Starship launch pads during static fire tests, when the rocket fires its engines while remaining on the ground. This is what prompted ULA and Blue Origin to lodge their protests.

“They understand neighboring operations,” Chatman said in a media roundtable on Friday. “They understand that we will allow the maximum efficiency possible to facilitate their operations, but there will be times that we’re not going to let them go to their launch complex because it’s neighboring a hazardous activity.”

The good news for these other companies is that Eastern Range’s keep-out zones will almost certainly get smaller by the time SpaceX gets anywhere close to 120 Starship launches per year. SpaceX’s Falcon 9 is currently launching at a similar cadence. The blast danger areas for those launches are small and short-lived because the Space Force’s confidence in the Falcon 9’s safety is “extremely high,” Chatman said.

“From a blast damage assessment perspective, specific to the Falcon 9, we know what that keep-out area is,” Chatman said. “It’s the new combination of new fuels—LOX/methane—which is kind of a game-changer as we look at some of the heavy vehicles that are coming to launch. We just don’t have the analysis on to be able to say, ‘Hey, from a testing perspective, how small can we reduce the BDA and be safe?’”

Methane has become a popular fuel choice, supplanting refined kerosene, liquid hydrogen, or solid fuels commonly used on previous generations of rockets. Methane leaves behind less soot than kerosene, easing engine reusability, while it’s simpler to handle than liquid hydrogen.

Aside from Starship, Blue Origin’s New Glenn and ULA’s Vulcan rockets use liquified natural gas, a fuel very similar to methane. Both rockets are smaller than Starship, but Blue Origin last week unveiled the design of a souped-up New Glenn rocket that will nearly match Starship’s scale.

A few years ago, NASA, the Space Force, and the Federal Aviation Administration decided to look into the explosive potential of methalox rockets. There had been countless tests of explosions of gaseous methane, but data on detonations of liquid methane and liquid oxygen was scarce at the time—just a couple of tests at less than 10 metric tons, according to NASA. So, the government’s default position was to assume an explosion would be equivalent to the energy released by the same amount of TNT. This assumption drives the large keep-out zones the Space Force has drawn around SpaceX’s future Starship launch pads, one of which is seen in the map below.

This map from a Space Force environmental impact statement shows potential restricted access zones around SpaceX’s proposed Starship launch site at Space Launch Complex-37. The restricted zones cover launch pads operated by United Launch Alliance, Relativity Space, and Stoke Space. Credit: SpaceX

Spending millions to blow stuff up

Chatman said the Space Force is prepared to update its blast danger areas once its government partners, SpaceX, and Blue Origin complete testing and analyze their results. Over dozens of tests, engineers are examining how methane and liquid oxygen react to different kinds of accidents, such as impact velocity, pressure, mass ratio, or how much propellant is in the mix.

“That is ongoing currently,” Chatman said. “[We are] working in close partnership with SpaceX and Blue Origin on the LOX/methane combination and the explicit equivalency to identify how much we can … reduce that blast radius. Those discussions are happening, have been happening the last couple years, and are looking to culminate here in ’26.

“Until we get that data from the testing that is ongoing and the analysis that needs to occur, we’re going to continue to treat any LOX-methane vehicle with 100 percent TNT blast equivalency, and have a maximized keep-out zone, simply from a public safety perspective,” Chatman said.

The data so far show promising results. “We do expect that BDA to shrink,” he said. “We expect that to shrink based on some of the initial testing that has been done and the initial data reviews that have been done.”

That’s imperative, not just for Starship’s neighbors at the Cape Canaveral spaceport, but for SpaceX itself. The company forecasts a future in which it will launch Starships more often than the Falcon 9, requiring near-continuous operations at multiple launch pads.

Chatman mentioned one future scenario in which SpaceX might want to launch Starships in close proximity to one another from neighboring pads.

“At that point in the future, I do anticipate the blast damage assessments to shrink down based on the testing that will have been accomplished and dataset will have been reviewed, [and] that we’ll be in a comfortable set to be able to facilitate all launch operations. But until we have that data, until I’m comfortable with what that data shows, with regards to reducing the BDA, keep-out zone, we’re going to continue with the 100 percent TNT equivalency just from a public safety perspective.”

SpaceX has performed explosive LOX/methane tests, including the one seen here, at its development facility in McGregor, Texas. Credit: SpaceX

The Commercial Space Federation, a lobbying group, submitted written testimony to Congress in 2023 arguing the government should be using “existing industry data” to inform its understanding of the explosive potential methane and liquid oxygen. That data, the federation said, suggests the government should set its TNT blast equivalency to no greater than 25 percent, a change that would greatly reduce the size of keep-out zones around launch pads. The organization’s members include prominent methane users SpaceX, Blue Origin, Relativity Space, and Stoke Space, all of which have launch sites at Cape Canaveral.

The government’s methalox testing plans were expected to cost at least $80 million, according to the Commercial Space Federation.

The concern among engineers is that liquid oxygen and methane are highly miscible, meaning they mix together easily, raising the risk of a “condensed phase detonation” with “significantly higher overpressures” than rockets with liquid hydrogen or kerosene fuels. Small-scale mixtures of liquid oxygen and liquified natural gas have “shown a broad detonable range with yields greater than that of TNT,” NASA wrote in 2023.

SpaceX released some basic results of its own methalox detonation tests in September, before the government draws its own conclusions on the matter. The company said it conducted “extensive testing” to refine blast danger areas to “be commensurate with the physics of new launch systems.”

Like the Commercial Space Federation, SpaceX said government officials are relying on “highly conservative approaches to establishing blast danger areas, simply because they lack the data to make refined, accurate clear zones. In the absence of data, clear areas of LOX/methane rockets have defaulted to very large zones that could be disruptive to operations.”

More like an airport

SpaceX said it has conducted sub-scale methalox detonation tests “in close collaboration with NASA,” while also gathering data from full-scale Starship tests in Starbase, Texas, including information from test flights and from recent ground test failures. SpaceX controls much of the land around its South Texas facility, so there’s little interruption to third parties when Starships launch from there.

“With this data, SpaceX has been able to establish a scientifically robust, physics-based yield calculation that will help ‘fill the gap’ in scientific knowledge regarding LOX/methane rockets,” SpaceX said.

The company did not disclose the yield calculation, but it shared maps showing its proposed clear areas around the future Starship launch sites at Cape Canaveral and Kennedy Space Center. They are significantly smarter than the clear areas originally envisioned by the Space Force and NASA, but SpaceX says it uses “actual test data on explosive yield and include a conservative factor of safety.”

The proposed clear distances will have no effect on any other operational launch site or on traffic on the primary north-south road crossing the spaceport, the company said. “SpaceX looks forward to having an open, honest, and reasonable discussion based on science and data regarding spaceport operations with industry colleagues.”

SpaceX will have that opportunity next month. The Space Force and NASA are convening a “reverse industry day” in mid-December during which launch companies will bring their ideas for the future of the Cape Canaveral spaceport to the government. The spaceport has hosted 101 space launches so far this year, an annual record dominated by SpaceX’s rapid-fire Falcon 9 launch cadence.

Chatman anticipates about the same number—perhaps 100 to 115 launches—from Florida’s Space Coast next year, and some forecasts show 300 to 350 launches per year by 2035. The numbers could go down before they rise again. “As we bring on larger lift capabilities like Starship and follow-on large launch capabilities out here to the Eastern Range, that will reduce the total number of launches, because we can get more mass to orbit with heavier lift vehicles,” Chatman said.

Blue Origin’s first recovered New Glenn booster returned to the company’s launch pad at Cape Canaveral, Florida, last week after a successful launch and landing. Credit: Blue Origin

Launch companies have some work to do to make those numbers become real. Space Force officials have identified their own potential bottlenecks, including a shortage of facilities for preparing satellites for launch and the flow of commodities like propellants and high-pressure gases into the spaceport.

Concerns as mundane as traffic jams are now enough of a factor to consider using automated scanners at vehicle inspection points and potentially adding a dedicated lane for slow-moving transporters carrying rocket boosters from one place to another across the launch base, according to Chatman. This is becoming more important as SpaceX, and now Blue Origin, routinely shuttle their reusable rockets from place to place.

Space Force officials largely attribute the steep climb in launch rates at Cape Canaveral to the launch industry’s embrace of automated self-destruct mechanisms. These pyrotechnic devices have largely replaced manual flight termination systems, which require ground support from a larger team of range safety engineers, including radar operators and flight control officers with the authority to send a destruct command to the rocket if it flies off course. Now, that is all done autonomously on most US launch vehicles.

The Space Force mandated that launch companies using military spaceports switch to autonomous safety systems by October 1 2025, but military officials issued waivers for human-in-the-loop destruct devices to continue flying on United Launch Alliance’s Atlas V rocket, NASA’s Space Launch System, and the US Navy’s ballistic missile fleet. That means those launches will be more labor-intensive for the Space Force, but the Atlas V is nearing retirement, and the SLS and the Navy only occasionally appear on the Cape Canaveral launch schedule.

Listing image: SpaceX

Stephen Clark is a space reporter at Ars Technica, covering private space companies and the world’s space agencies. Stephen writes about the nexus of technology, science, policy, and business on and off the planet.

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With another record broken, the world’s busiest spaceport keeps getting busier

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It’s not just the number of rocket launches, but how much stuff they’re carrying into orbit.

With 29 Starlink satellites onboard, a Falcon 9 rocket streaks through the night sky over Cape Canaveral Space Force Station, Florida, on Monday night. Credit: Stephen Clark/Ars Technica

CAPE CANAVERAL, Florida—Another Falcon 9 rocket fired off its launch pad here on Monday night, taking with it another 29 Starlink Internet satellites to orbit.

This was the 94th orbital launch from Florida’s Space Coast so far in 2025, breaking the previous record for the most satellite launches in a calendar year from the world’s busiest spaceport. Monday night’s launch came two days after a Chinese Long March 11 rocket lifted off from an oceangoing platform on the opposite side of the world, marking humanity’s 255th mission to reach orbit this year, a new annual record for global launch activity.

As of Wednesday, a handful of additional missions have pushed the global figure this year to 259, putting the world on pace for around 300 orbital launches by the end of 2025. This will more than double the global tally of 135 orbital launches in 2021.

Routine vs. complacency

Waiting in the darkness a few miles away from the launch pad, I glanced around at my surroundings before watching SpaceX’s Falcon 9 thunder into the sky. There were no throngs of space enthusiasts anxiously waiting for the rocket to light up the night. No line of photographers snapping photos. Just this reporter and two chipper retirees enjoying what a decade ago would have attracted far more attention.

Go to your local airport and you’ll probably find more people posted up at a plane-spotting park at the end of the runway. Still, a rocket launch is something special. On the same night that I watched the 94th launch of the year depart from Cape Canaveral, Orlando International Airport saw the same number of airplane departures in just three hours.

The crowds still turn out for more meaningful launches, such as a test flight of SpaceX’s Starship megarocket in Texas or Blue Origin’s attempt to launch its second New Glenn heavy-lifter here Sunday. But those are not the norm. Generations of aerospace engineers were taught that spaceflight is not routine for fear of falling into complacency, leading to failure, and in some cases, death.

Compared to air travel, the mantra remains valid. Rockets are unforgiving, with engines operating under extreme pressures, at high thrust, and unable to suck in oxygen from the atmosphere as a reactant for combustion. There are fewer redundancies in a rocket than in an airplane.

The Falcon 9’s established failure rate is less than 1 percent, well short of any safety standard for commercial air travel but good enough to be the most successful orbital-class in history. Given the Falcon 9’s track record, SpaceX seems to have found a way to overcome the temptation for complacency.

A Chinese Long March 11 rocket carrying three Shiyan 32 test satellites lifts off from waters off the coast of Haiyang in eastern China’s Shandong province on Saturday. Credit: Guo Jinqi/Xinhua via Getty Images

Following the trend

The upward trend in rocket launches hasn’t always been the case. Launch numbers were steady for most of the 2010s, following a downward trend in the 2000s, with as few as 52 orbital launches in 2005, the lowest number since the nascent era of spaceflight in 1961. There were just seven launches from here in Florida that year.

The numbers have picked up dramatically in the last five years as SpaceX has mastered reusable rocketry.

It’s important to look at not just the number of launches but also how much stuff rockets are actually putting into orbit. More than half of this year’s launches were performed using SpaceX’s Falcon 9 rocket, and the majority of those deployed Starlink satellites for SpaceX’s global Internet network. Each spacecraft is relatively small in size and weight, but SpaceX stacks up to 29 of them on a single Falcon 9 to max out the rocket’s carrying capacity.

All this mass adds up to make SpaceX’s dominance of the launch industry appear even more absolute. According to analyses by BryceTech, an engineering and space industry consulting firm, SpaceX has launched 86 percent of all the world’s payload mass over the 18 months from the beginning of 2024 through June 30 of this year.

That’s roughly 2.98 million kilograms of the approximately 3.46 million kilograms (3,281 of 3,819 tons) of satellite hardware and cargo that all the world’s rockets placed into orbit during that timeframe.

The charts below were created by Ars Technica using publicly available launch numbers and payload mass estimates from BryceTech. The first illustrates the rising launch cadence at Cape Canaveral Space Force Station and NASA’s Kennedy Space Center, located next to one another in Florida. Launches from other US-licensed spaceports, primarily Vandenberg Space Force Base, California, and Rocket Lab’s base at Māhia Peninsula in New Zealand, are also on the rise.

These numbers represent rockets that reached low-Earth orbit. We didn’t include test flights of SpaceX’s Starship rocket in the chart because all of its launches to have intentionally flown on suborbital trajectories.

In the second chart, we break down the payload upmass to orbit from SpaceX, other US companies, China, Russia, and other international launch providers.

Launch rates are on a clear upward trend, while SpaceX has launched 86 percent of the world’s total payload mass to orbit since the beginning of 2024. Credit: Stephen Clark/Ars Technica/BryceTech

Will it continue?

It’s a good bet that payload upmass will continue to rise in the coming years, with heavy cargo heading to orbit to further expand SpaceX’s Starlink communications network and build out new megaconstellations from Amazon, China, and others. The US military’s Golden Dome missile defense shield will also have a ravenous appetite for rockets to get it into space.

SpaceX’s Starship megarocket could begin flying to low-Earth orbit next year, and if it does, SpaceX’s preeminence in delivering mass to orbit will remain assured. Starship’s first real payloads will likely be SpaceX’s next-generation Starlink satellites. These larger, heavier, more capable spacecraft will launch 60 at a time on Starship, further stretching SpaceX’s lead in the upmass war.

But Starship’s arrival will come at the expense of the workhorse Falcon 9, which lacks the capacity to haul the next-gen Starlinks to orbit. “This year and next year I anticipate will be the highest Falcon launch rates that we will see,” said Stephanie Bednarek, SpaceX’s vice president of commercial sales, at an industry conference in July.

SpaceX is on pace for between 165 and 170 Falcon 9 launches this year, with 144 flights already in the books for 2025. Last year’s total for Falcon 9 and Falcon Heavy was 134 missions. SpaceX has not announced how many Falcon 9 and Falcon Heavy launches it plans for next year.

Starship is designed to be fully and rapidly reusable, eventually enabling multiple flights per day. But that’s still a long way off, and it’s unknown how many years it might take for Starship to surpass the Falcon 9’s proven launch tempo.

A Starship rocket and Super Heavy booster lift off from Starbase, Texas. Credit: SpaceX

In any case, with Starship’s heavy-lifting capacity and upgraded next-gen satellites, SpaceX could match an entire year’s worth of new Starlink capacity with just two fully loaded Starship flights. Starship will be able to deliver 60 times more Starlink capacity to orbit than a cluster of satellites riding on a Falcon 9.

There’s no reason to believe SpaceX will be satisfied with simply keeping pace with today’s Starlink growth rate. There are emerging market opportunities in connecting satellites with smartphones, space-based computer processing and data storage, and military applications.

Other companies have medium-to-heavy rockets that are either new to the market or soon to debut. These include Blue Origin’s New Glenn, now set to make its second test flight in the coming days, with a reusable booster designed to facilitate a rapid-fire launch cadence.

Despite all of the newcomers, most satellite operators see a shortage of launch capacity on the commercial market. “The industry is likely to remain supply-constrained through the balance of the decade,” wrote Caleb Henry, director of research at the industry analysis firm Quilty Space. “That could pose a problem for some of the many large constellations on the horizon.”

United Launch Alliance’s Vulcan rocket, Rocket Lab’s Neutron, Stoke Space’s Nova, Relativity Space’s Terran R, and Firefly Aerospace and Northrop Grumman’s Eclipse are among the other rockets vying for a bite at the launch apple.

“Whether or not the market can support six medium to heavy lift launch providers from the US alone—plus Starship—is an open question, but for the remainder of the decade launch demand is likely to remain high, presenting an opportunity for one or more new players to establish themselves in the pecking order,” Henry wrote in a post on Quilty’s website.

China’s space program will need more rockets, too. That nation’s two megaconstellations, known as Guowang and Qianfan, will have thousands of satellites requiring a significant uptick on Chinese launches.

Taking all of this into account, the demand curve for access to space is sure to continue its upward trajectory. How companies meet this demand, and with how many discrete departures from Earth, isn’t quite as clear.

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NASA’s next Moonship reaches last stop before launch pad

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The Orion spacecraft, which will fly four people around the Moon, arrived inside the cavernous Vehicle Assembly Building at NASA’s Kennedy Space Center in Florida late Thursday night, ready to be stacked on top of its rocket for launch early next year.

The late-night transfer covered about 6 miles (10 kilometers) from one facility to another at the Florida spaceport. NASA and its contractors are continuing preparations for the Artemis II mission after the White House approved the program as an exception to work through the ongoing government shutdown, which began on October 1.

The sustained work could set up Artemis II for a launch opportunity as soon as February 5 of next year. Astronauts Reid Wiseman, Victor Glover, Christina Koch, and Jeremy Hansen will be the first humans to fly on the Orion spacecraft, a vehicle that has been in development for nearly two decades. The Artemis II crew will make history on their 10-day flight by becoming the first people to travel to the vicinity of the Moon since 1972.

Where things stand

The Orion spacecraft, developed by Lockheed Martin, has made several stops at Kennedy over the last few months since leaving its factory in May.

First, the capsule moved to a fueling facility, where technicians filled it with hydrazine and nitrogen tetroxide propellants, which will feed Orion’s main engine and maneuvering thrusters on the flight to the Moon and back. In the same facility, teams loaded high-pressure helium and ammonia coolant into Orion propulsion and thermal control systems.

The next stop was a nearby building where the Launch Abort System was installed on the Orion spacecraft. The tower-like abort system would pull the capsule away from its rocket in the event of a launch failure. Orion stands roughly 67 feet (20 meters) tall with its service module, crew module, and abort tower integrated together.

Teams at Kennedy also installed four ogive panels to serve as an aerodynamic shield over the Orion crew capsule during the first few minutes of launch.

The Orion spacecraft, with its Launch Abort System and ogive panels installed, is seen last month inside the Launch Abort System Facility at Kennedy Space Center, Florida. Credit: NASA/Frank Michaux

It was then time to move Orion to the Vehicle Assembly Building (VAB), where a separate team has worked all year to stack the elements of NASA’s Space Launch System rocket. In the coming days, cranes will lift the spacecraft, weighing 78,000 pounds (35 metric tons), dozens of stories above the VAB’s center aisle, then up and over the transom into the building’s northeast high bay to be lowered atop the SLS heavy-lift rocket.

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Starship will soon fly over towns and cities, but will dodge the biggest ones

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Starship’s next chapter will involve launching over Florida and returning over Mexico.

SpaceX’s Starship vehicle is encased in plasma as it reenters the atmosphere over the Indian Ocean on its most recent test flight in August. Credit: SpaceX

Some time soon, perhaps next year, SpaceX will attempt to fly one of its enormous Starship rockets from low-Earth orbit back to its launch pad in South Texas. A successful return and catch at the launch tower would demonstrate a key capability underpinning Elon Musk’s hopes for a fully reusable rocket.

In order for this to happen, SpaceX must overcome the tyranny of geography. Unlike launches over the open ocean from Cape Canaveral, Florida, rockets departing from South Texas must follow a narrow corridor to steer clear of downrange land masses.

All 10 of the rocket’s test flights so far have launched from Texas toward splashdowns in the Indian or Pacific Oceans. On these trajectories, the rocket never completes a full orbit around the Earth, but instead flies an arcing path through space before gravity pulls it back into the atmosphere.

If Starship’s next two test flights go well, SpaceX will likely attempt to send the soon-to-debut third-generation version of the rocket all the way to low-Earth orbit. The Starship V3 vehicle will measure 171 feet (52.1 meters) tall, a few feet more than Starship’s current configuration. The entire rocket, including its Super Heavy booster, will have a height of 408 feet (124.4 meters).

Starship, made of stainless steel, is designed for full reusability. SpaceX has already recovered and reflown Super Heavy boosters, but won’t be ready to recover the rocket’s Starship upper stage until next year, at the soonest.

That’s one of the next major milestones in Starship’s development after achieving orbital flight. SpaceX will attempt to bring the ship home to be caught back at the launch site by the launch tower at Starbase, Texas, located on the southernmost section of the Texas Gulf Coast near the US-Mexico border.

It was always evident that flying a Starship from low-Earth orbit back to Starbase would require the rocket to fly over Mexico and portions of South Texas. The rocket launches to the east over the Gulf of Mexico, so it must approach Starbase from the west when it comes in for a landing.

New maps published by the Federal Aviation Administration show where the first Starships returning to Texas may fly when they streak through the atmosphere.

Paths to and from orbit

The FAA released a document Friday describing SpaceX’s request to update its government license for additional Starship launch and reentry trajectories. The document is a draft version of a “tiered environmental assessment” examining the potential for significant environmental impacts from the new launch and reentry flight paths.

The federal regulator said it is evaluating potential impacts in aviation emissions and air quality, noise and noise-compatible land use, hazardous materials, and socioeconomics. The FAA concluded the new flight paths proposed by SpaceX would have “no significant impacts” in any of these categories.

SpaceX’s Starship rocket shortly before splashing into the Indian Ocean in August. Credit: SpaceX

The environmental review is just one of several factors the FAA considers when deciding whether to approve a new commercial launch or reentry license. According to the FAA, the other factors are public safety issues (such as overflight of populated areas and payload contents), national security or foreign policy concerns, and insurance requirements.

The FAA didn’t make a statement on any public safety and foreign policy concerns with SpaceX’s new trajectories, but both issues may come into play as the company seeks approval to fly Starship over Mexican towns and cities uprange from Starbase.

The regulator’s licensing rules state that a commercial launch and reentry should each pose no greater than a 1 in 10,000 chance of harming or killing a member of the public not involved in the mission. The risk to any individual should not exceed 1 in 1 million.

So, what’s the danger? If something on Starship fails, it could disintegrate in the atmosphere. Surviving debris would rain down to the ground, as it did over the Turks and Caicos Islands after two Starship launch failures earlier this year. Two other Starship flights ran into problems once in space, tumbling out of control and breaking apart during reentry over the Indian Ocean.

The most recent Starship flight last month was more successful, with the ship reaching its target in the Indian Ocean for a pinpoint splashdown. The splashdown had an error of just 3 meters (10 feet), giving SpaceX confidence in returning future Starships to land.

This map shows Starship’s proposed reentry corridor. Credit: Federal Aviation Administration

One way of minimizing the risk to the public is to avoid flying over large metropolitan areas, and that’s exactly what SpaceX and the FAA are proposing to do, at least for the initial attempts to bring Starship home from orbit. A map of a “notional” Starship reentry flight path shows the vehicle beginning its reentry over the Pacific Ocean, then passing over Baja California and soaring above Mexico’s interior near the cities of Hermosillo and Chihuahua, each with a population of roughly a million people.

The trajectory would bring Starship well north of the Monterrey metro area and its 5.3 million residents, then over the Rio Grande Valley near the Texas cities of McAllen and Brownsville. During the final segment of Starship’s return trajectory, the vehicle will begin a vertical descent over Starbase before a final landing burn to slow it down for the launch pad’s arms to catch it in midair.

In addition to Monterrey, the proposed flight path dodges overflights of major US cities like San Diego, Phoenix, and El Paso, Texas.

Let’s back up

Setting up for this reentry trajectory requires SpaceX to launch Starship into an orbit with exactly the right inclination, or angle to the equator. There are safety constraints for SpaceX and the FAA to consider here, too.

All of the Starship test flights to date have launched toward the east, threading between South Florida and Cuba, south of the Bahamas, and north of Puerto Rico before heading over the North Atlantic Ocean. For Starship to target just the right orbit to set up for reentry, the rocket must fly in a slightly different direction over the Gulf.

Another map released by the FAA shows two possible paths Starship could take. One of the options goes to the southeast between Mexico’s Yucatan Peninsula and the western tip of Cuba, then directly over Jamaica as the rocket accelerated into orbit over the Caribbean Sea. The other would see Starship departing South Texas on a northeasterly path and crossing over North Florida before reaching the Atlantic Ocean.

While both trajectories fly over land, they avoid the largest cities situated near the flight path. For example, the southerly route misses Cancun, Mexico, and the northerly path flies between Jacksonville and Orlando, Florida. “Orbital launches would primarily be to low inclinations with flight trajectories north or south of Cuba that minimize land overflight,” the FAA wrote in its draft environmental assessment.

The FAA analyzed two launch trajectory options for future orbital Starship test flights. Credit: Federal Aviation Administration

The proposed launch and reentry trajectories would result in temporary airspace closures, the FAA said. This could force delays or rerouting of anywhere from seven to 400 commercial flights for each launch, according to the FAA’s assessment.

Launch airspace closures are already the norm for Starship test flights. The FAA concluded that the reentry path over Mexico would require the closure of a swath of airspace covering more than 4,200 miles. This would affect up to 200 more commercial airplane flights during each Starship mission. Eventually, the FAA aims to shrink the airspace closures as SpaceX demonstrates improved reliability with Starship test flights.

Eventually, SpaceX will move some flights of Starship to Florida’s Space Coast, where rockets can safely launch in many directions over the Atlantic. By then, SpaceX aims to be launching Starships at a regular cadence—first, multiple flights per month, then per week, and then per day.

This will enable all of the things SpaceX wants to do with Starship. Chief among these goals is to fly Starships to Mars. Before then, SpaceX must master orbital refueling. NASA also has a contract with SpaceX to build Starships to land astronauts on the Moon’s south pole.

But all of that assumes SpaceX can routinely launch and recover Starships. That’s what engineers hope to soon prove they can do.

Starship will soon fly over towns and cities, but will dodge the biggest ones Read More »

NASA closing its original repository for Columbia artifacts to tours

apollo, artifacts, Challenger, CLC, Columbia Learning Center, Columbia Lessons Learned Program, Columbia Research and Preservation Office, debris, Kennedy Space Center, NASA, Operations Support Building-1, OSB-1, Space, Space exploration, space history, VAB, vehicle assembly building, wreckage / Kris Guyer / September 15, 2025

NASA is changing the way that its employees come in contact with, and remember, one of its worst tragedies.

In the wake of the 2003 loss of the space shuttle Columbia and its STS-107 crew, NASA created a program to use the orbiter’s debris for research and education at Kennedy Space Center in Florida. Agency employees were invited to see what remained of the space shuttle as a powerful reminder as to why they had to be diligent in their work. Access to the Columbia Research and Preservation Office, though, was limited as a result of its location and related logistics.

To address that and open up the experience to more of the workforce at Kennedy, the agency has quietly begun work to establish a new facility.

“The room, titled Columbia Learning Center (CLC), is a whole new concept,” a NASA spokesperson wrote in an email. “There are no access requirements; anyone at NASA Kennedy can go in any day of the week and stay as long as they like. The CLC will be available whenever employees need the inspiration and message for generations to come.”

Debris depository

On February 1, 2003, Columbia was making its way back from a 16-day science mission in Earth orbit when the damage that it suffered during its launch resulted in the orbiter breaking apart over East Texas. Instead of landing at Kennedy as planned, Columbia fell to the ground in more than 85,000 pieces.

The tragedy claimed the lives of commander Rick Husband, pilot Willie McCool, mission specialists David Brown, Kalpana Chawla, Michael Anderson, and Laurel Clark, and payload specialist Ilan Ramon of Israel.

NASA closing its original repository for Columbia artifacts to tours Read More »

Prepping for Starship, SpaceX is about to demolish one of ULA’s launch pads

Air Force, cape canaveral space force station, elon musk, Kennedy Space Center, launch, slc-37, Space, space force, spacex, starship / Rejus Almole / June 10, 2025

SpaceX may soon have up to nine active launch pads. Most competitors have one or two.

A Delta IV Heavy rocket stands inside the mobile service tower at Space Launch Complex-37 in this photo from 2014. SpaceX is set to demolish all of the structures seen here. Credit: United Launch Alliance

The US Air Force is moving closer to authorizing SpaceX to move into one of the largest launch pads at Cape Canaveral Space Force Station in Florida, with plans to use the facility for up to 76 launches of the company’s Starship rocket each year.

A draft Environmental Impact Statement (EIS) released this week by the Department of the Air Force, which includes the Space Force, found SpaceX’s planned use of Space Launch Complex 37 (SLC-37) at Cape Canaveral would have no significant negative impacts on local environmental, historical, social, and cultural interests. The Air Force also found SpaceX’s plans at SLC-37 will have no significant impact on the company’s competitors in the launch industry.

The Defense Department is leading the environmental review and approval process for SpaceX to take over the launch site, which the Space Force previously leased to United Launch Alliance, one of SpaceX’s chief rivals in the US launch industry. ULA launched its final Delta IV Heavy rocket from SLC-37 in April 2024, a couple of months after the military announced SpaceX was interested in using the launch pad.

Ground crews are expected to begin removing Delta IV-era structures at the launch pad this week. Multiple sources told Ars demolition could begin as soon as Thursday.

Emre Kelly, a Space Force spokesperson, deferred questions on the schedule for the demolition to SpaceX, which is overseeing the work. But he said the Delta IV’s mobile gantry, fixed umbilical tower, and both lightning towers will come down. Unlike other large-scale demolitions at Cape Canaveral, SpaceX and the Space Force don’t plan to publicize the event ahead of time.

“Demolition of these items will be conducted in accordance with federal and state laws that govern explosive demolition operations,” Kelly said.

In their place, SpaceX plans to build two 600-foot-tall (180-meter) Starship launch integration towers within the 230-acre confines of SLC-37.

Tied at the hip

The Space Force’s willingness to turn over a piece of prime real estate at Cape Canaveral to SpaceX helps illustrate the government’s close relationship with—indeed, reliance on—Elon Musk’s space company. The breakdown of Musk’s relationship with President Donald Trump has, so far, only spawned a war of words between the two billionaires.

But Trump has threatened to terminate Musk’s contracts with the federal government and warned of “serious consequences” for Musk if he donates money to Democratic political candidates. Musk said he would begin decommissioning SpaceX’s Dragon spacecraft, the sole US vehicle ferrying astronauts to and from orbit, before backing off the threat last week.

NASA and the Space Force need SpaceX’s Dragon spacecraft and its Falcon 9 and Falcon Heavy rockets to maintain the International Space Station and launch the nation’s most critical military satellites. The super heavy-lift capabilities Starship will bring to the government could enable a range of new missions, such as global cargo delivery for the military and missions to the Moon and Mars in partnership with NASA.

Fully stacked, the Starship rocket stands more than 400 feet tall. Credit: SpaceX

SpaceX already has a “right of limited entry” to begin preparations to convert SLC-37 into a Starship launch pad. A full lease agreement between the Space Force and SpaceX is expected after the release of the final Environmental Impact Statement.

The environmental approval process began more than a year ago with a notice of intent, followed by studies, evaluations, and scope meetings that fed into the creation of the draft EIS. Now, government officials will host more public meetings and solicit public comments on SpaceX’s plans through late July. Then, sometime this fall, the Department of the Air Force will issue a final EIS and a “record of decision,” according to the project’s official timeline.

A growing footprint

This timeline could allow SpaceX to begin launching Starships from SLC-37 as soon as next year, although the site still requires the demolition of existing structures and construction of new towers, propellant farms, a methane liquefaction plant, water tanks, deluge systems, and other ground support equipment. The construction will likely take more than a year, so perhaps 2027 is a more realistic target.

The company is also studying an option to construct two separate towers for use exclusively as “catch towers” for recovery of Super Heavy boosters and Starship upper stages “if space allows” at SLC-37, according to the draft EIS. According to the Air Force, the initial review process eliminated an option for SpaceX to construct a standalone Starship launch pad on undeveloped property at Cape Canaveral because the site would have a “high potential” for impacting endangered species and is “less ideal” than developing an existing launch pad.

SpaceX’s plan for recovering its reusable Super Heavy and Starship vehicles involves catching them with articulating arms on a tower—either a launch integration structure or a catch-only tower. SpaceX has already demonstrated catching the Super Heavy booster on three test flights at the company’s Starbase launch site in South Texas. An attempt to catch a Starship vehicle returning from low-Earth orbit might happen later this year, assuming SpaceX can correct the technical problems that have stalled the rocket’s advancement in recent months.

Construction crews are outfitting a second Starship launch tower at Starbase, called Pad B, that may also come online before the end of this year. A few miles north of SLC-37, SpaceX has built another Starship tower at Launch Complex 39A, a historic site on NASA property at Kennedy Space Center. Significant work remains ahead at LC-39A to install a new launch mount, finish digging a flame trench, and install all the tanks and plumbing necessary to store and load super-cold propellants into the rocket. The most recent official schedule from SpaceX suggests a first Starship launch from LC-39A could happen before the end of the year, but it’s probably a year or more away.

The Air Force’s draft Environmental Impact Statement includes this map showing SpaceX’s site plan for SLC-37. Credit: Department of the Air Force

Similar to the approach SpaceX is taking at SLC-37, a document released last year indicates the Starship team plans to construct a separate catch tower near the Starship launch tower at LC-39A. If built, these catch towers could simplify Starship operations as the flight rate ramps up, allowing SpaceX to catch a returning rocket at one location while stacking Starships for launch with the chopstick arms on nearby integration towers.

With SpaceX’s growing footprint in Texas and Florida, the company has built, is building, or revealed plans to build at least five Starship launch towers. This number is likely to grow in the coming years as Musk aims to eventually launch and land multiple Starships per day. This will be a gradual ramp-up as SpaceX works through Starship design issues, grows factory capacity, and brings new launch pads online.

Last month, the Federal Aviation Administration—which oversees environmental reviews for launch sites that aren’t on military property—approved SpaceX’s request to launch Starships as many as 25 times per year from Starbase, Texas. The previous limit was five, but the number will likely go up from here. Coming into 2025, SpaceX sought to launch as many as 25 Starships this year, but failures on three of the rockets’ most recent test flights have slowed development, and this goal is no longer achievable.

That’s a lot of launches

Meanwhile, in Florida, the FAA’s environmental review for LC-39A is assessing the impact of launching Starships up to 44 times per year from Kennedy Space Center. At nearby Cape Canaveral Space Force Station, the Air Force is evaluating SpaceX’s proposal for up to 76 Starship flights per year from SLC-37. The scope of each review also includes environmental assessments for Super Heavy and Starship landings within the perimeters of each launch complex.

While the draft EIS for SLC-37 is now public, the FAA hasn’t yet released a similar document for SpaceX’s planned expansion and Starship launch operations at LC-39A, also home to a launch pad used for Falcon 9 and Falcon Heavy flights.

SpaceX will continue launching its workhorse Falcon 9 and Falcon Heavy rockets as Starship launch pads heat up with more test flights. Within a few years, SpaceX could have as many as nine active launch pads spread across three states. The company’s most optimistic vision for Starship would require many more, potentially including offshore launch and landing sites.

At Vandenberg Space Force Base in California, SpaceX has leased the former West Coast launch pad for United Launch Alliance’s Delta IV rocket. SpaceX will prepare this launch pad, known as SLC-6, for Falcon 9 and Falcon Heavy launches starting as soon as next year, augmenting the capacity of the company’s existing Vandenberg launch pad, which is only configured for Falcon 9s. Like the demolition at SLC-37 in Florida, the work to prepare SLC-6 will include the razing of unnecessary towers and structures left over from the Delta IV (and the Space Shuttle) program.

SpaceX has not yet announced any plans to launch Starships from the California spaceport.

SpaceX launches Falcon 9 rockets from Pad 39A at NASA’s Kennedy Space Center and from Pad 40 at Cape Canaveral Space Force Station. The company plans to develop Starship launch infrastructure at Pad 39A and Pad 37. United Launch Alliance flies Vulcan and Atlas V rockets from Pad 41, and Blue Origin has based its New Glenn rocket at Pad 36. Credit: NASA (labels by Ars Technica)

The expansion of SpaceX’s launch facilities comes as most of its closest competitors limit themselves to just one or two launch pads. ULA has reduced its footprint from seven launch pads to two as a cost-cutting measure. Blue Origin, Jeff Bezos’ space company, operates a single launch pad at Cape Canaveral, although it has unannounced plans to open a launch facility at Vandenberg. Rocket Lab has three operational launch pads in New Zealand and Virginia for the light-class Electron rocket and will soon have a fourth in for the medium-lift Neutron launcher.

These were the top four companies in Ars’ most recent annual power ranking of US launch providers.

Two of these competitors, ULA and Blue Origin, complained last year that SpaceX’s target of launching as many as 120 Starships per year from Florida’s Space Coast could force them to clear their launch pads for safety reasons. The Space Force is responsible for ensuring all personnel remain outside of danger areas during testing and launch operations.

It could become quite busy at Cape Canaveral. Military officials forecast that launch providers not named SpaceX could fly more than 110 launches per year. The Air Force acknowledged in the draft EIS that SpaceX’s plans for up to 76 launches and 152 landings (76 Starships and 76 Super Heavy boosters) per year at SLC-37 “could result in planning constraints for other range user operations.” This doesn’t take into account the FAA’s pending approval for up to 44 Starship flights per year from LC-39A.

But the report suggests SpaceX’s plans to launch from SLC-37 won’t require the evacuation of ULA and Blue Origin’s launch pads. While the report doesn’t mention the specific impact of Starship launches on ULA and Blue Origin, the Air Force wrote that work could continue on SpaceX’s own Falcon 9 launch pad at SLC-40 during a Starship launch at SLC-37. Because SLC-40 is closer to SLC-37 than ULA and Blue Origin’s pads, this finding seems to imply workers could remain at those launch sites.

The Air Force’s environmental report also doesn’t mention possible impacts of Starship launches from NASA property on nearby workers. It also doesn’t include any discussion of how Starship launches from SLC-37 might affect workers’ access to other facilities, such as offices and hangars, closer to the launch pad.

The bottom line of this section of the Air Force’s environmental report concluded that Starship flights from SLC-37 “should have no significant impact” on “ongoing and future activities” at the spaceport.

Shipping Starships

While SpaceX builds out its Starship launch pads on the Florida coast, the company is also constructing a Starship integration building a few miles away at Kennedy Space Center. This structure, called Gigabay, will be located next to an existing SpaceX building used for Falcon 9 processing and launch control.

The sprawling Gigabay will stand 380 feet tall and provide approximately 46.5 million cubic feet of interior processing space with 815,000 square feet of workspace, according to SpaceX. The company says this building should be operational by the end of 2026. SpaceX is also planning a co-located Starship manufacturing facility, similar to the Starfactory building recently completed at Starbase, Texas.

Until this factory is up and running, SpaceX plans to transport Starships and Super Heavy boosters horizontally via barges from South Texas to Cape Canaveral.

Prepping for Starship, SpaceX is about to demolish one of ULA’s launch pads Read More »

As preps continue, it’s looking more likely NASA will fly the Artemis II mission

artemis, artemis II, human spaceflight, Kennedy Space Center, launch, moon, NASA, Science, Space, space launch system / Tim Belzer / March 25, 2025

NASA’s existing architecture still has a limited shelf life, and the agency will probably have multiple options for transporting astronauts to and from the Moon in the 2030s. A decision on the long-term future of SLS and Orion isn’t expected until the Trump administration’s nominee for NASA administrator, Jared Isaacman, takes office after confirmation by the Senate.

So, what is the plan for SLS?

There are different degrees of cancellation options. The most draconian would be an immediate order to stop work on Artemis II preparations. This is looking less likely than it did a few months ago and would come with its own costs. It would cost untold millions of dollars to disassemble and dispose of parts of Artemis II’s SLS rocket and Orion spacecraft. Canceling multibillion-dollar contracts with Boeing, Northrop Grumman, and Lockheed Martin would put NASA on the hook for significant termination costs.

Of course, these liabilities would be less than the $4.1 billion NASA’s inspector general estimates each of the first four Artemis missions will cost. Most of that money has already been spent for Artemis II, but if NASA spends several billion dollars on each Artemis mission, there won’t be much money left over to do other cool things.

Other options for NASA might be to set a transition point when the Artemis program would move off of the Space Launch System rocket, and perhaps even the Orion spacecraft, and switch to new vehicles.

Looking down on the Space Launch System for Artemis II. Credit: NASA/Frank Michaux

Another possibility, which seems to be low-hanging fruit for Artemis decision-makers, could be to cancel the development of a larger Exploration Upper Stage for the SLS rocket. If there are a finite number of SLS flights on NASA’s schedule, it’s difficult to justify the projected $5.7 billion cost of developing the upgraded Block 1B version of the Space Launch System. There are commercial options available to replace the rocket’s Boeing-built Exploration Upper Stage, as my colleague Eric Berger aptly described in a feature story last year.

For now, it looks like NASA’s orange behemoth has a little life left in it. All the hardware for the Artemis II mission has arrived at the launch site in Florida.

The Trump administration will release its fiscal year 2026 budget request in the coming weeks. Maybe, then, NASA will also have a permanent administrator, and the veil will lift over the White House’s plans for Artemis.

As preps continue, it’s looking more likely NASA will fly the Artemis II mission Read More »

NASA is stacking the Artemis II rocket, implying a simple heat shield fix

artemis, artemis II, human spaceflight, Kennedy Space Center, NASA, orion, Science, Space, space launch system, vehicle assembly building / Tim Belzer / November 21, 2024

A good sign

The readiness of the Orion crew capsule, where the four Artemis II astronauts will live during their voyage around the Moon, is driving NASA’s schedule for the mission. Officially, Artemis II is projected to launch in September of next year, but there’s little chance of meeting that schedule.

At the beginning of this year, NASA officials ruled out any opportunity to launch Artemis II in 2024 due to several technical issues with the Orion spacecraft. Several of these issues are now resolved, but NASA has not released any meaningful updates on the most significant problem.

This problem involves the Orion spacecraft’s heat shield. During atmospheric reentry at the end of the uncrewed Artemis I test flight in 2022, the Orion capsule’s heat shield eroded and cracked in unexpected ways, prompting investigations by NASA engineers and an independent panel.

NASA’s Orion heat shield inquiry ran for nearly two years. The investigation has wrapped up, two NASA officials said last month, but they declined to discuss any details of the root cause of the heat shield issue or the actions required to resolve the problem on Artemis II.

These corrective options ranged from doing nothing to changing the Orion spacecraft’s reentry angle to mitigate heating or physically modifying the Artemis II heat shield. In the latter scenario, NASA would have to disassemble the Orion spacecraft, which is already put together and is undergoing environmental testing at Kennedy Space Center. This would likely delay the Artemis II launch by a couple of years.

In August, NASA’s top human exploration official told Ars that the agency would hold off on stacking the SLS rocket until engineers had a good handle on the heat shield problem. There are limits to how long the solid rocket boosters can remain stacked vertically. The joints connecting each segment of the rocket motors are certified for one year. This clock doesn’t actually start ticking until NASA stacks the next booster segments on top of the lowermost segments.

However, NASA waived this rule on Artemis I when the boosters were stacked nearly two years before the successful launch.

A NASA spokesperson told Ars on Wednesday that the agency had nothing new to share on the Orion heat shield or what changes, if any, are required for the Artemis II mission. This information should be released before the end of the year, she said. At the same time, NASA could announce a new target launch date for Artemis II at the end of 2025, or more likely in 2026.

But because NASA gave the “go” for SLS stacking now, it seems safe to rule out any major hardware changes on the Orion heat shield for Artemis II.

NASA is stacking the Artemis II rocket, implying a simple heat shield fix Read More »

Rocket delivered to launch site for first human flight to the Moon since 1972

artemis, artemis II, human spaceflight, Kennedy Space Center, NASA, Science, SLS core stage, Space, space launch system / Paul Patrick / July 27, 2024

The central piece of NASA’s second Space Launch System rocket arrived at Kennedy Space Center in Florida this week. Agency officials intend to start stacking the towering launcher in the next couple of months for a mission late next year carrying a team of four astronauts around the Moon.

The Artemis II mission, officially scheduled for September 2025, will be the first voyage by humans to the vicinity of the Moon since the last Apollo lunar landing mission in 1972. NASA astronauts Reid Wiseman, Victor Glover, Christina Koch, and Canadian mission specialist Jeremy Hansen will ride the SLS rocket away from Earth, then fly around the far side of the Moon and return home inside NASA’s Orion spacecraft.

“The core is the backbone of SLS, and it’s the backbone of the Artemis mission,” said Matthew Ramsey, NASA’s mission manager for Artemis II. “We’ve been waiting for the core to get here because all the integrated tests and checkouts that we do have to have the core stage. It has the flight avionics that drive the whole system. The boosters are also important, but the core is really the backbone for Artemis. So it’s a big day.”

The core stage rolled off of NASA’s Pegasus barge at Kennedy early Wednesday, following a weeklong ocean voyage from New Orleans, where Boeing builds the rocket under contract to NASA.

Ramsey told Ars that ground teams hope to begin stacking the rocket’s two powerful solid rocket boosters on NASA’s mobile launcher platform in September. Each booster, supplied by Northrop Grumman, is made of five segments with pre-packed solid propellant and a nose cone. All the pieces for the SLS boosters are at Kennedy and ready for stacking, Ramsey said.

The SLS upper stage, built by United Launch Alliance, is also at the Florida launch site. Now, the core stage is at Kennedy. In August or September, NASA plans to deliver the two remaining elements of the SLS rocket to Florida. These are the adapter structures that will connect the core stage to the upper stage, and the upper stage to the Orion spacecraft.

A heavy-duty crane inside the cavernous Vehicle Assembly Building (VAB) will hoist each segment of the SLS boosters into place on the launch platform. Once the boosters are fully stacked, ground teams will lift the 212-foot (65-meter) core stage vertical in the transfer aisle running through the center of the VAB. A crane will then lower the core stage between the boosters. That could happen as soon as December, according to Ramsey.

Then comes the launch vehicle stage adapter, the upper stage, the Orion stage adapter, and finally, the Orion spacecraft itself.

Moving toward operations

NASA’s inspector general reported in 2022 that NASA’s first four Artemis missions will each cost $4.1 billion. Subsequent documents, including a Government Accountability Office report last year, suggest the expendable SLS core stage is responsible for at least a quarter of the cost for each Artemis flight.

The core stage for Artemis II is powered by four hydrogen-fueled RS-25 engines produced by Aerojet Rocketdyne. Two of the reusable engines for Artemis II have flown on the space shuttle, and the other two RS-25s were built in the shuttle era but never flew. Each SLS launch will put the core stage and its engines in the Atlantic Ocean.

Steve Wofford, who manages the stages office for the SLS program at NASA’s Marshall Space Flight Center, told Ars there are “no major configuration differences” between the core stages for Artemis I and Artemis II. The only minor differences involve instrumentation that NASA wanted on Artemis I to measure pressures, accelerations, vibrations, temperatures, and other parameters on the first flight of the Space Launch System.

“We are still working off some flight observations that we made on Artemis I, but no showstoppers,” Wofford said. “On the first article, the test flight, Artemis I, we really loaded it up. That’s a golden opportunity to learn as much as you can about the vehicle and the flight regime, and anchor all your models… As you progress, you need less and less of that. So Core Stage 2 will have less development flight instrumentation than Core Stage 1, and then Core Stage 3 will have less still.”

Rocket delivered to launch site for first human flight to the Moon since 1972 Read More »

We take a stab at decoding SpaceX’s ever-changing plans for Starship in Florida

artemis, cape canaveral, Commercial space, Features, Federal Aviation Administration, Kennedy Space Center, launch, launch complex 39a, NASA, Science, Space, spacex, starship / Mike M. / May 20, 2024

SpaceX's Starship tower (left) at Launch Complex 39A dwarfs the launch pad for the Falcon 9 rocket (right). — Enlarge / SpaceX’s Starship tower (left) at Launch Complex 39A dwarfs the launch pad for the Falcon 9 rocket (right).

There are a couple of ways to read the announcement from the Federal Aviation Administration that it’s kicking off a new environmental review of SpaceX’s plan to launch the most powerful rocket in the world from Florida.

The FAA said on May 10 that it plans to develop an Environmental Impact Statement (EIS) for SpaceX’s proposal to launch Starships from NASA’s Kennedy Space Center in Florida. The FAA ordered this review after SpaceX updated the regulatory agency on the projected Starship launch rate and the design of the ground infrastructure needed at Launch Complex 39A (LC-39A), the historic launch pad once used for Apollo and Space Shuttle missions.

Dual environmental reviews

At the same time, the US Space Force is overseeing a similar EIS for SpaceX’s proposal to take over a launch pad at Cape Canaveral Space Force Station, a few miles south of LC-39A. This launch pad, designated Space Launch Complex 37 (SLC-37), is available for use after United Launch Alliance’s last Delta rocket lifted off there in April.

On the one hand, these environmental reviews often take a while and could cloud Elon Musk’s goal of having Starship launch sites in Florida ready for service by the end of 2025. “A couple of years would not be a surprise,” said George Nield, an aerospace industry consultant and former head of the FAA’s Office of Commercial Space Transportation.

Another way to look at the recent FAA and Space Force announcements of pending environmental reviews is that SpaceX finally appears to be cementing its plans to launch Starship from Florida. These plans have changed quite a bit in the last five years.

The environmental reviews will culminate in a decision on whether to approve SpaceX’s proposals for Starship launches at LC-39A and SLC-37. The FAA will then go through a separate licensing process, similar to the framework used to license the first three Starship test launches from South Texas.

NASA has contracts with SpaceX worth more than $4 billion to develop a human-rated version of Starship to land astronauts on the Moon on the first two Artemis lunar landing flights later this decade. To do that, SpaceX must stage a fuel depot in low-Earth orbit to refuel the Starship lunar lander before it heads for the Moon. It will take a series of Starship tanker flights—perhaps 10 to 15—to fill the depot with cryogenic propellants.

Launching that many Starships over the course of a month or two will require SpaceX to alternate between at least two launch pads. NASA and SpaceX officials say the best way to do this is by launching Starships from one pad in Texas and another in Florida.

Earlier this week, Ars spoke with Lisa Watson-Morgan, who manages NASA’s human-rated lunar lander program. She was at Kennedy Space Center this week for briefings on the Starship lander and a competing lander from Blue Origin. One of the topics, she said, was the FAA’s new environmental review before Starship can launch from LC-39A.

“I would say we’re doing all we can to pull the schedule to where it needs to be, and we are working with SpaceX to make sure that their timeline, the EIS timeline, and NASA’s all work in parallel as much as we can to achieve our objectives,” she said. “When you’re writing it down on paper just as it is, it looks like there could be some tight areas, but I would say we’re collectively working through it.”

Officially, SpaceX plans to perform a dress rehearsal for the Starship lunar landing in late 2025. This will be a full demonstration, with refueling missions, an uncrewed landing of Starship on the lunar surface, then a takeoff from the Moon, before NASA commits to putting people on Starship on the Artemis III mission, currently slated for September 2026.

So you can see that schedules are already tight for the Starship lunar landing demonstration if SpaceX activates launch pads in Florida late next year.

We take a stab at decoding SpaceX’s ever-changing plans for Starship in Florida Read More »

The US military’s spaceplane is about to fly again—it needs a bigger rocket

Boeing, falcon heavy, Kennedy Space Center, launch, Space, spacex, X-37b / Rejus Almole / December 11, 2023

SpaceX's Falcon Heavy rocket stands on Launch Complex 39A in Florida, hours before its scheduled liftoff with the military's X-37B spaceplane. — Enlarge / SpaceX’s Falcon Heavy rocket stands on Launch Complex 39A in Florida, hours before its scheduled liftoff with the military’s X-37B spaceplane.

Trevor Mahlmann/Ars Technica

CAPE CANAVERAL, Florida—A SpaceX Falcon Heavy rocket is poised for launch as soon as Tuesday night from the Kennedy Space Center in Florida, and the US military’s mysterious X-37B spaceplane is fastened atop the heavy-lifter for a ride into orbit.

Although the Space Force is keeping details about the military spaceplane’s flight under wraps, we know it’s heading into an unusual orbit, probably significantly higher than the X-37B’s previous sojourns that stayed within a few hundred miles of Earth’s surface.

SpaceX’s launch team called off a launch attempt Monday night “due to a ground side issue” and reset for another launch opportunity as soon as Tuesday night at 8: 14pm EST (01: 14 UTC). When it lifts off, the Falcon Heavy will light 27 kerosene-fueled engines to power the rocket off its launch pad overlooking the Atlantic coastline.

You can watch the launch using SpaceX’s live video feed on X, the social media platform, or if you prefer YouTube, third-party streams are available from Spaceflight Now and NASASpaceflight.

The exact altitude the X-37B will be flying through is unclear, but hobbyists and amateur sleuths who use open source information to reconstruct trajectories of top-secret military spacecraft suggest the Falcon Heavy will haul the winged vehicle into an orbit that could stretch tens of thousands of miles above the planet.

What’s more, the Falcon Heavy will apparently take a flight path toward the northeast from Florida’s Space Coast, then ultimately release the X-37B on a trajectory that will take it over Earth’s polar regions. This is a significant departure from the flight profile for the military spaceplane’s six previous missions, which all flew to space on smaller rockets than the Falcon Heavy.

In a statement, the Space Force said this flight of the X-37B is focused on “a wide range of test and experimentation objectives.” Flying in “new orbital regimes” is among the test objectives, military officials said.

“It seems to me like it might be a much higher orbit that it’s going to,” said Brian Weeden, director of program planning for the Secure World Foundation, which promotes sustainable and peaceful uses of outer space. “Otherwise, I don’t know why they would use a Falcon Heavy, which is a pretty big thing.”

Covering more ground

The X-37B spaceplane has attracted a lot of attention and speculation since its first mission in 2010. Across multiple administrations, Pentagon officials have consistently walked a narrow line between acknowledging the existence of the spaceplane, and divulging limited information about its general purpose, while treating some details with the utmost secrecy. The military does not talk about where in space it flies. With a few exceptions, defense officials haven’t publicly discussed specifics of what the X-37B carries into orbit.

The military has two Boeing-built X-37B spaceplanes, or Orbital Test Vehicles, in its inventory. They are reusable and designed to launch inside the payload fairing of a conventional rocket, spend multiple years in space with the use of solar power, and then return to Earth for a landing on a three-mile-long runway, either at Vandenberg Space Force Base in California or at NASA’s Kennedy Space Center in Florida.

It resembles a miniature version of NASA’s retired space shuttle orbiter, with wings, deployable landing gear, and black thermal protection tiles to shield its belly from the scorching heat of reentry. It measures 29 feet (about 9 meters) long, roughly a quarter of the length of NASA’s space shuttle, and it doesn’t carry astronauts. The X-37B has a cargo bay inside the fuselage for payloads, with doors that open after launch and close before landing.

The Space Force made a surprise announcement on November 8 that the next flight of the X-37B, sometimes called OTV-7, would launch on a SpaceX Falcon Heavy rocket. All six of the spaceplane’s past flights launched on smaller rockets, either United Launch Alliance’s Atlas V or SpaceX’s Falcon 9.

The US military’s spaceplane is about to fly again—it needs a bigger rocket Read More »