Kennedy Space Center

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

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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.

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

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

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.”

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

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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.

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

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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.

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