Space

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China begins launching a megaconstellation, and it sounds a lot like Starlink

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Sailing in LEO —

Like Starlink, China’s Qianfan satellites have an easy-to-pack flat-panel design.

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A Long March 6A rocket launches the first 18 Internet satellites for China's Qianfan, or Thousand Sails, broadband network.

Enlarge / A Long March 6A rocket launches the first 18 Internet satellites for China’s Qianfan, or Thousand Sails, broadband network.

Chinese officials have long signaled their interest in deploying a satellite network, or maybe several, to beam broadband Internet signals across China and other nations within its sphere of influence.

Two serious efforts are underway in China to develop a rival to SpaceX’s Starlink network, which the Chinese government has banned in its territory. The first batch of 18 satellites for one of those Chinese networks launched into low-Earth orbit Tuesday.

A Long March 6A rocket delivered the 18 spacecraft into a polar orbit following liftoff at 2: 42 am EDT (06: 42 UTC) from the Taiyuan launch base in northern China’s Shanxi province. The Long March 6A is one of China’s newest rockets—and the country’s first to employ strap-on solid rocket boosters—with the ability to deploy a payload of up to 4.5 metric tons (9,900 pounds) into a 700-kilometer (435-mile) Sun-synchronous orbit.

The rocket placed its payload of 18 Qianfan satellites into the proper orbit, and the launch mission was a complete success, according to the China Aerospace Science and Technology Corporation, the largest state-owned contractor for the Chinese space program.

Qianfan translates to “Thousand Sails,” and the 18 satellites launched Tuesday are the first of potentially thousands of spacecraft planned by Shanghai Spacecom Satellite Technology (SSST), a company backed by Shanghai’s municipal government. The network developed by SSST is also called the “Spacesail Constellation.”

Shanghai officials only began releasing details of this constellation last year. A filing with the International Telecommunication Union suggests the developers of Shanghai-based megaconstellation initially plan to deploy 1,296 satellites at an altitude of about 1,160 kilometers (721 miles).

Xinhua, China’s state-run news agency, said the constellation “will provide global users with low-latency, high-speed and ultra-reliable satellite broadband Internet services.”

Opening the floodgates?

SSST’s network was previously known as G60 Starlink, referencing a major cross-country highway in China and the project’s intent to imitate SpaceX’s broadband service.

Thousand Sails may eventually consist of more than 14,000 satellites, but like other Internet megaconstellations, the size of the fleet will likely grow at a rate commensurate with demand. It will take many years for SSST to deploy a 14,000-satellite constellation, if it ever does. SpaceX has rolled out several generations of Starlink satellites to offer new services and more capacity to meet customer uptake.

Chinese officials have released few details about the Qianfan satellites. But the project’s backers have said the spacecraft has a “standardized and modular” flat-panel design. “It meets the needs of stacking multiple satellites with one rocket,” said Shanghai Gesi Aerospace Technology, a joint venture set up by SSST and the Chinese Academy of Sciences to oversee manufacturing of Qianfan satellites.

This sounds a lot like the design of SpaceX’s Starlink satellites, which are flat-packed for launch on Falcon 9 rockets. SpaceX pioneered this way of launching and deploying large numbers of satellites. The approach used for Starlink, and apparently for Qianfan, streamlines the integration of multiple satellites with their launcher on the ground. It also simplifies their separation from the rocket once in orbit.

The new Qianfan satellite factory in Shanghai can produce up to 300 spacecraft per year, project officials said in December. Officials previously said the first 108 satellites for the Thousand Sails constellation would launch this year.

SSST announced in February it had raised more than $900 million from Chinese state-backed investment funds, Shanghai’s municipal government, and sources of venture capital. SSST’s origin is linked to a Chinese joint venture with a Germany-based company called KLEO Connect, which intended to develop a smaller constellation of low-Earth orbit satellites for data relay services.

China launched four technology demonstration satellites, purportedly related to the KLEO Connect venture, to test telecom hardware and electric propulsion systems in orbit. The joint venture fell apart with a flurry of lawsuits, and the German government last year blocked a complete takeover of KLEO Connect by its Chinese investors.

Now, SSST is going it alone with the Thousand Sails network. It has rapidly scaled up satellite manufacturing capacity in Shanghai. But outside of Starlink, companies with ideas for megaconstellations have run into serious headwinds.

OneWeb filed for bankruptcy in 2020 before eventually launching its entire first-generation network of 633 Internet satellites. Amazon has pushed back the full-scale deployment of its Project Kuiper megaconstellation, and the launch of the first operational Kuiper Internet satellites may be delayed again to 2025. The future of the European Union’s IRIS² satellite Internet network is in doubt after disagreements among European governments on funding the project.

The Thousand Sails constellation is less well-known than another planned Chinese satellite Internet network known as Guowang, or “national network,” which is supported by China’s central government. Guowang is owned by a state-backed company called SatNet, and its architecture will consist of 13,000 satellites. However, China has not yet launched any spacecraft for the Guowang project.

It’s unclear if the Thousand Sails network and the Guowang constellation will be direct competitors. They could be geared to different segments of the broadband market. In either case, China’s restrictive Internet policies with terrestrial networks will likely spill over into the satellite segment.

Chinese officials recognize the military utility of satellite Internet services like Starlink, which has supported Ukrainian military forces fighting Russian troops since 2022. A homegrown Starlink-like service would, no doubt, prove useful for China’s military.

Alongside potential domestic civilian users, China could use its satellite Internet networks as a diplomatic tool to build on existing partnerships between the Chinese government and developing countries. This could “lead to a leapfrogging moment, where African countries opt for the Chinese Internet constellation over Western providers due to the fact that much of their infrastructure is already Chinese-built,” the Royal United Services Institute, a UK think tank, wrote in a report last year.

While there are open questions about how China will use its satellite megaconstellations, their deployment will require a significant increase in the country’s launch capacity, driving the development of new commercial rockets, including reusable boosters, to lower costs and increase their flight rate.

China begins launching a megaconstellation, and it sounds a lot like Starlink Read More »

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NASA likely to significantly delay the launch of Crew 9 due to Starliner issues

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Boeing's Starliner spacecraft is lifted to be placed atop an Atlas V rocket for its first crewed launch.

Enlarge / Boeing’s Starliner spacecraft is lifted to be placed atop an Atlas V rocket for its first crewed launch.

United Launch Alliance

NASA is planning to significantly delay the launch of the Crew 9 mission to the International Space Station due to ongoing concerns about the Starliner spacecraft currently attached to the station.

While the space agency has not said anything publicly, sources say NASA should announce the decision this week. Officials are contemplating moving the Crew-9 mission from its current date of August 18 to September 24, a significant slip.

Nominally, this Crew Dragon mission will carry NASA astronauts Zena Cardman, spacecraft commander; Nick Hague, pilot; and Stephanie Wilson, mission specialist; as well as Roscosmos cosmonaut Alexander Gorbunov, for a six-month journey to the space station. However, NASA has been considering alternatives to the crew lineup—possibly launching with two astronauts instead of four—due to ongoing discussions about the viability of Starliner to safely return astronauts Butch Wilmore and Suni Williams to Earth.

As of late last week, NASA still had not decided whether the Starliner vehicle, which is built and operated by Boeing, should be used to fly its two crew members home. During its launch and ascent to the space station two months ago, five small thrusters on the Starliner spacecraft failed. After extensive ground testing of the thrusters, as well as some brief in-space firings, NASA had planned to make a decision last week on whether to return Starliner with crew. However, a Flight Readiness Review planned for last Thursday was delayed after internal disagreements at NASA about the safety of Starliner.

At issue is the performance of the small reaction control system thrusters in proximity to the space station. If the right combination of them fail before Starliner has moved sufficiently far from the station, Starliner could become uncontrollable and collide with the space station. The thrusters are also needed later in the flight back to Earth to set up the critical de-orbit burn and entry in Earth’s atmosphere.

Software struggles

NASA has quietly been studying the possibility of crew returning in a Dragon for more than a month. As NASA and Boeing engineers have yet to identify a root cause of the thruster failure, the possibility of Wilmore and Williams returning on a Dragon spacecraft has increased in the last 10 days. NASA has consistently said that ‘crew safety’ will be its No. 1 priority in deciding how to proceed.

The Crew 9 delay is relevant to the Starliner dilemma for a couple of reasons. One, it gives NASA more time to determine the flight-worthiness of Starliner. However, there is also another surprising reason for the delay—the need to update Starliner’s flight software. Three separate, well-placed sources have confirmed to Ars that the current flight software on board Starliner cannot perform an automated undocking from the space station and entry into Earth’s atmosphere.

At first blush, this seems absurd. After all, Boeing’s Orbital Flight Test 2 mission in May 2022 was a fully automated test of the Starliner vehicle. During this mission, the spacecraft flew up to the space station without crew on board and then returned to Earth six days later. Although the 2022 flight test was completed by a different Starliner vehicle, it clearly demonstrated the ability of the program’s flight software to autonomously dock and return to Earth. Boeing did not respond to a media query about why this capability was removed for the crew flight test.

NASA likely to significantly delay the launch of Crew 9 due to Starliner issues Read More »

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Rocket Report: Falcon 9 is back; Starship could be recovered off Australia

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Starship down under —

Elon Musk doesn’t expect the next Starship test flight to occur before late August.

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Welcome to Edition 7.05 of the Rocket Report! The Federal Aviation Administration grounded SpaceX’s Falcon 9 rocket for 15 days after a rare failure of its upper stage earlier this month. The FAA gave the green light for Falcon 9 to return to flight July 25, and within a couple of days, SpaceX successfully launched three missions from three launch pads. There’s a lot on Falcon 9’s to-do list, so we expect SpaceX to quickly return to form with several flights per week.

As always, we welcome reader submissions. If you don’t want to miss an issue, please subscribe using the box below (the form will not appear on AMP-enabled versions of the site). Each report will include information on small-, medium-, and heavy-lift rockets as well as a quick look ahead at the next three launches on the calendar.

Big delay for a reusable rocket testbed. The French space agency, CNES, has revealed that the inaugural test flight of its Callisto reusable rocket demonstrator will not take place until late 2025 or early 2026, European Spaceflight reports. CNES unveiled an updated website for the Callisto rocket program earlier this month, showing the test rocket has been delayed from a debut launch later this year to until late 2025 or early 2026. The Callisto rocket is designed to test techniques and technologies required for reusable rockets, such as vertical takeoff and vertical landing, with suborbital flights from the Guiana Space Center in South America.

Cooperative action … Callisto, which stands for Cooperative Action Leading to Launcher Innovation in Stage Toss-back Operations, is a joint project between CNES, German space agency DLR, and JAXA, the Japanese space agency. It will stand 14 meters (46 feet) tall and weigh about 4 metric tons (8,800 pounds), with an engine supplied by Japan. Callisto is one of several test projects in Europe aiming to pave the way for a future reusable rocket. (submitted by EllPeaTea and Ken the Bin)

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Small step for Themis. Another European project established to demonstrate reusable rocket tech is making slow progress toward a first flight. The Themis project, funded by the European Space Agency, is similar in purpose to the Callisto testbed discussed above. This week, the German aerospace manufacturing company MT Aerospace announced it has begun testing a demonstrator of the landing legs that will be used aboard the Themis reusable booster, European Spaceflight reports. The landing legs for Themis are made of carbon fiber-reinforced plastic composites, and the initial test demonstrated good deployment and showed it would withstand the impact energy of landing.

Also delayed … Like Callisto, Themis is facing delays in getting to the launch pad. ArianeGroup, the ESA-selected Themis prime contractor, had been expected to conduct an initial hop test of the demonstrator before the end of 2024. However, officials have announced the initial hop tests won’t happen until sometime next year. The Themis booster is intended to eventually become the first stage booster for an orbital-class partially reusable rocket being developed by MaiaSpace, a subsidiary of ArianeGroup. (submitted by Ken the Bin)

Falcon 9 is flying again. A SpaceX Falcon 9 rocket returned to flight on July 27, barely two weeks after an upper stage failure ended a streak of more than 300 consecutive successful launches, Ars reports. By some measures this was an extremely routine mission—it was, after all, SpaceX’s 73rd launch of this calendar year. And like many other Falcon 9 launches this year, the “Starlink 10-9” mission carried 23 of the broadband Internet satellites into orbit. However, after a rare failure earlier this month, this particular Falcon 9 rocket was making a return-to-flight for the company and attempting to get the world’s most active booster back into service.

Best part is no part … The Falcon 9 successfully deployed its payload of Starlink satellites about an hour after lifting off from NASA’s Kennedy Space Center in Florida. Later in the weekend, SpaceX launched two more Starlink missions on Falcon 9 rockets from Florida and California, notching three flights in less than 28 hours. The launch failure on the previous Falcon 9 launch was caused by a liquid oxygen leak on the upper stage, which led to a “hard start” on the upper stage engine when it attempted to reignite in flight. Engineers and technicians were quickly able to pinpoint the cause of the leak, a crack in a “sense line” for a pressure sensor attached to the vehicle’s liquid oxygen system.

Atlas V’s NSSL era is over. United Launch Alliance delivered a classified US military payload to orbit Tuesday for the last time with an Atlas V rocket, ending the Pentagon’s use of Russian rocket engines as national security missions transition to all-American launchers, Ars reports. This was the 101st launch of an Atlas V rocket since its debut in 2002, and the 58th and final Atlas V mission with a US national security payload since 2007. The Atlas V is powered by an RD-180 main engine made in Russia, and with a little prodding from SpaceX (via a lawsuit) and Congress, the Pentagon started making moves to end its reliance on the RD-180 a decade ago.

Other options available … The RD-180 never failed on a National Security Space Launch (NSSL) mission using the Atlas V rocket, but its use became politically untenable after Russia’s annexation of Crimea in 2014, which predated Russia’s full-scale invasion of Ukraine eight years later. SpaceX began launching US military missions in 2018, and ULA debuted its new Vulcan rocket in January. Assuming a successful second test flight of Vulcan in September, ULA’s next-generation rocket has a good shot at launching its first national security mission by the end of the year. The Space Force’s policy is to maintain at least two independent launch vehicles capable of flying military payloads into orbit. Vulcan and SpaceX’s Falcon rocket family fulfill that requirement, so the military no longer needs the Atlas V. However, 15 more Atlas V rockets remain in ULA’s inventory for future commercial flights.

Crackdown at the Cape. While this week’s landmark launch of the Atlas V rocket is worthy of celebration, there’s a new ULA policy that deserves ridicule, Ars reports. Many of the spectacular photos of rocket launches shared on social media come from independent photographers, who often make little to no money working for an established media organization. Instead, they rely on sales of prints to recoup at least some of their expenses for gas, food, and camera equipment needed to capture these images, which often serve as free publicity for launch providers like ULA. Last month, ULA announced it will no longer permit these photographers to set up remote cameras at their launch pads if they sell their images independently. This new policy was in place for the Atlas V launch from Cape Canaveral, Florida, on Tuesday morning.

But why? … “ULA will periodically confirm editorial publication for media participating in remote camera placement,” ULA stated in an email distributed to photographers last month. “If publication does not occur, or photos are sold outside of editorial purposes, privileges to place remote cameras may be revoked.” To the photographers who spend many hours preparing their equipment, waiting to set up and remove cameras, and persevering through scrubs and more, it seemed like a harsh judgment. And nobody knows why it happened. ULA has offered no public comment about the new policy, and the company did not respond to questions from Ars about the agreement.

Astroscale achieves a first in orbit. There are more than 2,000 mostly intact dead rockets circling the Earth, but until this year, no one ever launched a satellite to go see what one looked like after many years of tumbling around the planet, Ars reports. A Japanese company named Astroscale launched a small satellite in February to chase down the derelict upper stage from a Japanese H-IIA rocket. Astroscale’s ADRAS-J spacecraft arrived near the H-IIA upper stage in April, and the company announced this week that its satellite has now completed two 360-degree fly-arounds of the rocket. This is the first time a satellite has maneuvered around an actual piece of space junk, and it offers an unprecedented snapshot of how an abandoned rocket holds up to 15 years in the harsh environment of space.

Prepping for the future … Astroscale’s ADRAS-J mission is partially funded by the Japan Aerospace Exploration Agency (JAXA). Astroscale and JAXA also have a contract for a follow-up mission named ADRAS-J2, which will attempt to link up with the same H-IIA rocket and steer it on a trajectory to burn up in Earth’s atmosphere. This would be the first demonstration of active debris removal, a concept pursued by Astroscale and other companies to help clear space junk out of low-Earth orbit.

An update on Ariane 6. The European Space Agency has released its first update on the results from the first flight of the Ariane 6 rocket since its launch July 9. Europe’s new flagship rocket had a mostly successful inaugural test flight. Its first stage, solid rocket boosters, and upper stage performed as expected for the first phase of the flight, delivering eight small satellites into an on-target orbit. The launch pad at the Guiana Space Center in South America also held up to the violent environment of launch, ESA said.

Still investigating … However, the final phase of the mission didn’t go according to plan. The upper stage’s Vinci engine was supposed to reignite for a third time on the test flight to deorbit the rocket, which would have released two small reentry capsules on technology demonstration missions to test heat shield technologies. This didn’t happen. An Auxiliary Propulsion Unit, which is a small engine to provide additional bursts of thrust and pressurize the upper stage’s propellant tanks, shut down shortly after startup ahead of the third burn of the primary Vinci engine. “This meant the Vinci engine’s third boost could not take place,” ESA said. “Analysis of the APU’s behavior is ongoing and further information will be made available as soon as possible, while the next task force update is expected in September.” (submitted by Ken the Bin)

Room to grow at Starbase. SpaceX has since launched Starship four times from its launch site in South Texas, known as Starbase, and is planning a fifth launch within the next two months, Ars reports. However, as it continues to test Starship and make plans for regular flights, SpaceX will need a higher flight rate. This is especially true as the company is unlikely to activate additional launch pads for Starship in Florida until at least 2026. To that end, SpaceX has asked the FAA for permission for up to 25 flights a year from South Texas, as well as the capability to land both the Starship upper stage and Super Heavy booster stage back at the launch site.

The answer is probably yes … On Monday, the FAA signaled that it is inclined to grant this request. The agency released a draft assessment indicating that its extensive 2022 analysis of Starship launch activities on the environment, wildlife, local communities, and more was sufficient to account for SpaceX’s proposal for more launches. There is more to do for this conclusion to become official, including public meetings and a public comment period this month.

SpaceX eyes Australia. SpaceX is in talks with US and Australian officials to land and recover one of its Starship rockets off Australia’s coast, a possible first step toward a bigger presence for Elon Musk’s company in the region as the two countries bolster security ties, Reuters reports. At the end of SpaceX’s fourth Starship test flight in June, the rocket made a controlled splashdown in the Indian Ocean hundreds of miles off the northwest coast of Australia. The discussions now underway are focused on the possibility of towing a future Starship vehicle from its splashdown point in the ocean to a port in Australia, where SpaceX engineers could inspect it and learn more about how it performed.

Eventually, it’ll come back to land … On the next Starship flight, currently planned for no earlier than late August, SpaceX plans to attempt to recover Starship’s giant Super Heavy booster using catch arms on the launch pad tower in Texas. On Sunday, Elon Musk told SpaceX and Tesla enthusiasts at an event called the “X Takeover” that it will take a few more flights for engineers to get comfortable returning the Starship itself to a landing onshore. “We want to be really confident that the ship heat shield is super robust and lands at the exact right location,” he said. “So before we try to bring the ship back to the launch site, we probably want to have at least three successful landings of the ship [at sea].” (submitted by Ken the Bin)

Next three launches

August 2: Electron | “Owl for One, One for Owl” | Mahia Peninsula, New Zealand | 16: 39 UTC

August 3: Falcon 9 | NG-21 | Cape Canaveral Space Force Station, Florida | 15: 28 UTC

August 4: Falcon 9 | Starlink 11-1 | Vandenberg Space Force Base, California | 07: 00 UTC

Listing image by SpaceX

Rocket Report: Falcon 9 is back; Starship could be recovered off Australia Read More »

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NASA says it is “evaluating all options” for the safe return of Starliner crew

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Boeing's Starliner spacecraft is seen docked at the International Space Station on June 13.

Enlarge / Boeing’s Starliner spacecraft is seen docked at the International Space Station on June 13.

It has now been eight weeks since Boeing’s Starliner spacecraft launched into orbit on an Atlas V rocket, bound for the International Space Station. At the time NASA officials said the two crew members, Butch Wilmore and Suni Williams, could return to Earth as soon as June 14, just eight days later.

Yes, there had been some problems on Starliner’s ride to the space station that involved helium leaks and failing thrusters. But officials said they were relatively minor and sought to downplay them. “Those are pretty small, really, issues to deal with,” Mark Nappi, vice president and manager of Boeing’s Commercial Crew Program, said during a post-docking news conference. “We’ll figure them out for the next mission. I don’t see these as significant at all.”

But days turned to weeks, and weeks turned to months as NASA and Boeing continued to study the two technical problems. Of these issues, the more pressing concern was the failure of multiple reaction control system thrusters that are essential to steering Starliner during its departure from the space station and setting up a critical engine burn to enter Earth’s atmosphere.

In the last few weeks, ground teams from NASA and Boeing completed testing of a thruster on a test stand at White Sands, New Mexico. Then, last weekend, Boeing and NASA fired the spacecraft’s thrusters in orbit to check their performance while docked at the space station. NASA has said preliminary results from these tests were helpful.

Dragon becomes a real option

One week ago, the last time NASA officials spoke to the media, the agency’s program manager for commercial crew, Steve Stich, would not be drawn into discussing what would happen should NASA conclude that Starliner’s thrusters were not reliable enough for the return journey to Earth.

“Our prime option is to complete the mission,” Stich said one week ago. “There are a lot of good reasons to complete this mission and bring Butch and Suni home on Starliner. Starliner was designed, as a spacecraft, to have the crew in the cockpit.”

For a long time, it seemed almost certain that the astronauts would return to Earth inside Starliner. However, there has been a lot of recent activity at NASA, Boeing, and SpaceX that suggests that Wilmore and Williams could come home aboard a Crew Dragon spacecraft rather than Starliner. Due to the critical importance of this mission, Ars is sharing what we know as of Thursday afternoon.

One informed source said it was greater than a 50-50 chance that the crew would come back on Dragon. Another source said it was significantly more likely than not they would. To be clear, NASA has not made a final decision. This probably will not happen until at least next week. It is likely that Jim Free, NASA’s associate administrator, will make the call.

Asked if it was now more likely than not that Starliner’s crew would return on Dragon, NASA spokesperson Josh Finch told Ars on Thursday evening, ” NASA is evaluating all options for the return of agency astronauts Butch Wilmore and Suni Williams from the International Space Station as safely as possible. No decisions have been made and the agency will continue to provide updates on its planning.”

NASA says it is “evaluating all options” for the safe return of Starliner crew Read More »

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There are 2,000-plus dead rockets in orbit—here’s a rare view of one

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Astroscale's ADRAS-J spacecraft captured these views of the H-IIA rocket upper stage on July 15.

Enlarge / Astroscale’s ADRAS-J spacecraft captured these views of the H-IIA rocket upper stage on July 15.

There are more than 2,000 mostly intact dead rockets circling the Earth, but until this year, no one ever launched a satellite to go see what one looked like after many years of tumbling around the planet.

In February, a Japanese company named Astroscale sent a small satellite into low-Earth orbit on top of a Rocket Lab launcher. A couple of months later, Astroscale’s ADRAS-J (Active Debris Removal by Astroscale-Japan) spacecraft completed its pursuit of a Japanese rocket stuck in orbit for more than 15 years.

ADRAS-J photographed the upper stage of an H-IIA rocket from a range of several hundred meters and then backed away. This was the first publicly released image of space debris captured from another spacecraft using rendezvous and proximity operations.

Since then, Astroscale has pulled off more complex maneuvers around the H-IIA upper stage, which hasn’t been controlled since it deployed a Japanese climate research satellite in January 2009. Astroscale attempted to complete a 360-degree fly-around of the H-IIA rocket last month, but the spacecraft triggered an autonomous abort one-third through the maneuver after detecting an attitude anomaly.

ADRAS-J flew away from the H-IIA rocket for several weeks. After engineers determined the cause of the glitch that triggered the abort, ADRAS-J fired thrusters to approach the upper stage again this month. The ADRAS-J spacecraft is about the size of a kitchen oven, while the H-IIA rocket it’s visiting is nearly the size of a city bus.

Astroscale’s satellite completed two fly-around maneuvers of the H-IIA upper stage on July 15 and 16, examining all sides of the rocket as it soared more than 350 miles (560 kilometers) above the planet. Engineers also wanted to measure the upper stage’s spin rate and spin axis. At first glance, the upper stage appears remarkably similar to the way it looked when it launched. Despite exposure to the harsh conditions of space, the rocket’s outer skin remains covered in orange foam insulation, and the engine nozzle still shines as if it were new.

ADRAS-J autonomously maneuvered around the rocket at a distance of about 50 meters (164 feet), using navigation data from a light detection and ranging sensor and Astroscale’s custom-developed guidance algorithms to control its position as the vehicles moved around Earth at nearly 4.7 miles per second (7.6 kilometers per second). This is the crux of the challenge for ADRAS-J because the rocket is unpowered and unable to hold position. The upper stage also lacks laser reflectors and targets that would aid an approaching spacecraft.

This is a first

These types of complex maneuvers, known as rendezvous and proximity operations (RPO), are common for crew and cargo spacecraft around the International Space Station. Other commercial satellites have demonstrated formation-flying and even docking with a spacecraft that wasn’t designed to connect with another vehicle in orbit.

Military satellites from the United States, Russia, and China also have RPO capabilities, but as far as we know, these spacecraft have only maneuvered in ultra-close range around so-called “cooperative” objects designed to receive them. In 2003, the Air Force Research Laboratory launched a small satellite named XSS-10 to inspect the upper stage of a Delta II rocket in orbit, but it had a head start. XSS-10 maneuvered around the same rocket that deployed it, rather than pursuing a separate target.

There are 2,000-plus dead rockets in orbit—here’s a rare view of one Read More »

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Human muscle cells come back from space, look aged

Biology, gene activity, muscle cells, Science, Space, Space exploration / /

Putting some muscle into it —

Astronauts’ muscles atrophy in space, but we can identify the genes involved.

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Image of two astronauts in an equipment filled chamber, standing near the suits they wear for extravehicular activities.

Enlarge / Muscle atrophy is a known hazard of spending time on the International Space Station.

Muscle-on-chip systems are three-dimensional human muscle cell bundles cultured on collagen scaffolds. A Stanford University research team sent some of these systems to the International Space Station to study the muscle atrophy commonly observed in astronauts.

It turns out that space triggers processes in human muscles that eerily resemble something we know very well: getting old. “We learned that microgravity mimics some of the qualities of accelerated aging,” said Ngan F. Huang, an associate professor at Stanford who led the study.

Space-borne bioconstructs

“This work originates from our lab’s expertise in regenerative medicine and tissue engineering. We received funding to do a tissue engineering experiment on the ISS, which really helped us embark on this journey, and became curious how microgravity affects human health,” said Huang. So her team got busy designing the research equipment needed to work onboard the space station. The first step was building the muscle-on-chip systems.

“A lot of what was known about how space affects muscles was gathered through studying the astronauts or studying animals like mice put in microgravity for research purposes,” Huang said. “In some cases, there were also in vitro cultured cells on a Petri dish—something very basic. We wanted to have something more structurally complex.” Her team developed a muscle-on-chip platform in which human myotubes, cells that organize into long parallel bundles that eventually become muscle fibers in a living organism, were grown on collagen scaffolds. The goal was to make the samples emulate real muscles better. But that came with a challenge: keeping them alive on the ISS.

“When we grow cells on Earth, we pour the medium—basically a liquid with nutrients that allow the cells to grow—over the cells, and everything is fine,” Huang said. “But in space, in the absence of gravity, we needed a closed, leak-proof, tightly sealed chamber. The medium was sloshed around in there.”

Oxygen and carbon dioxide levels were maintained with permeable membranes. Changing the medium was a complicated procedure involving syringes and small custom-designed ports. But getting all this gadgetry up and running was worth it in the end.

Genes of atrophy

Huang’s team had two sets of muscle-on-chip systems: one on the ground and one on the ISS. The idea of the study was to compare the genes that were upregulated or downregulated in each sample set. It turned out that many genes associated with aging saw their activity increase in microgravity conditions.

This result was confirmed when the team analyzed the medium that was taken off after the cells had grown in it. “The goal was to identify proteins released by the cells that were associated with microgravity. Among those, the most notable was the GDF15, which is relevant to different diseases, particularly mitochondrial dysfunction or senescence,” said Huang.

Overall, the condition of cells on the ISS was somewhat similar to sarcopenia, an age-related muscle loss disease. “There were some similarities, but also a lot of differences. The reason we didn’t make sarcopenia the main focus of this study is that we know our muscle-on-chip system is a model. It’s mostly muscle cells on a scaffold. It doesn’t have blood vessels or nerves. Comparing that to clinical, real muscle samples is a bit tricky, as it is not comparing apples to apples,” said Huang.

Nevertheless, her team went on to use their ISS muscle-on-chip samples to conduct proof-of-concept drug screening tests. Drugs they tested included those used to treat sarcopenia, among other conditions.

Space drugs

“One of the drugs we tested was the [protein] IGF 1, which is a growth factor naturally found in the body in different tissues, especially in muscles. When there is an injury, IGF 1 activates within a body to initiate muscle regeneration. Also, IGF 1 tend to be declined in aging muscles,” said Huang. The second drug tested was 15-PGDH-i, a relatively new inhibitor of enzymes that hinder the process of muscle regeneration. Used on the muscles-on-chip on the ISS, the drugs partially reduced some of the microgravity-related effects.

“One of the limitations of this work was that on the ISS, the microgravity is also accompanied by other factors, such as ionizing radiation, and it is hard to dissociate one from the other,” said Huang. It’s still unclear if the effects observed in the ISS samples were there due to radiation, the lack of gravity, both, or some additional factor. Huang’s team plans to do similar experiments on Earth in simulated microgravity conditions. “With some of the specialized equipment we recently acquired, it is possible to look at just the effects of microgravity,” Huang said. Those experiments are aimed at testing a wider range of drugs.

“The reason we do this drug screening is to develop drugs that could either be taken preemptively or during the flight to counteract muscle atrophy. It would probably be more feasible, lighter, and cheaper than doing artificial gravity concepts,” Huang said. The most promising candidate drugs selected in these ground experiments will be tested on Huang’s muscle-on-chip systems onboard the ISS in 2025.

Stem Cell Reports, 2024. DOI: 10.1016/j.stemcr.2024.06.010

Human muscle cells come back from space, look aged Read More »

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NASA’s Lunar Gateway has a big visiting vehicles problem

lunar gateway, NASA, Science, Space / /

Stack controllability —

“These defects could lead the flight computers to unexpectedly restart.”

–

A rendering of NASA's proposed lunar gateway.

Enlarge / A rendering of NASA’s proposed lunar gateway.

NASA

Do you remember the Lunar Gateway? You could be forgiven if not, as the program continues to be tossed around by NASA planners, and it is still not entirely clear what purpose the lunar space station is supposed to serve.

The Gateway—a small space station that will fly in a halo orbit around the Moon and spend most of its time far from the lunar surface—was initially supposed to launch in 2022. That obviously did not happen, and now, according to a new report from the US Government Accountability Office, the space agency does not expect the launch of the initial elements of the Gateway until at least December 2027. The baseline cost estimate is $5.3 billion.

NASA’s present plans contemplate using the Gateway as part of the Artemis IV mission, presently scheduled for September 2028. Unfortunately, the Gateway’s current launch target is already three months later than needed to support Artemis IV, the second mission to land humans on the Moon. But that’s OK. There are a lot of other moving parts for this mission, so a launch any time this decade would be a win.

The report includes a helpful cartoon to explain the complicated sequence that needs to happen for Gateway to be involved in the Artemis IV mission:

  • Launch of the initial segments of the Gateway, a power and propulsion module, and a habitation module, to a halo orbit around the Moon
  • Launch of a SpaceX Dragon XL vehicle to bring supplies to the Gateway
  • Launch of multiple SpaceX Starships to fuel a Lunar Starship, which will then fly to and dock with the Gateway
  • Launch of a NASA Space Launch System rocket carrying four astronauts inside an Orion spacecraft as well as another Gateway module
  • After launch, Orion separates from the rocket and docks with this module, the International Habitat
  • Orion tugs the International Habitat to the Gateway and docks; the crew exits onto Gateway
  • Two crew members board the Lunar Starship and go down to the Moon for six days
  • Starship flies back to the Gateway, and the four astronauts return to Earth inside Orion.
How the Artemis IV mission will (probably) take place.

How the Artemis IV mission will (probably) take place.

US GAO

In a rather understated manner, the report notes that this plan is fairly complex and faces some serious schedule risks.

“This mission will be complex because NASA will need to coordinate across seven NASA programs, multiple contractors that support those programs, and international partners to execute the mission,” the report states. “It will also be the first launch of an upgraded version of the Space Launch System rocket.”

Developmental difficulties

The report also finds that the Gateway program is running into some pretty serious technical difficulties. One involves a defective network chip that facilitates communication throughout the lunar space station. Its failure could cause myriad problems onboard the Gateway.

“For example, these defects could lead the flight computers to unexpectedly restart,” the report states. “If the network is not functioning properly, it could result in loss of control of the Gateway. Program officials are also concerned that they might identify more defects with the communication network, based on the number found already.”

Another risk involves something called “stack controllability.” This essentially means that because SpaceX’s Lunar Starship is so much more massive than the Gateway, when it is docked to the space station, the Gateway’s power and propulsion element (PPE) will not be able to maintain a proper orientation of the entire stack.

“Program officials estimate that the mass of the lunar lander Starship is approximately 18 times greater than the value NASA used to develop the PPE’s controllability parameters,” the report states. “According to NASA’s system engineering guidance, late requirements and design changes can lead to cost growth and schedule delays.”

The report also has some sobering conclusions about the potential utility of the Lunar Gateway for Mars missions. (In the past, NASA officials have spoken about the Gateway as a staging area for spacecraft and propellant for human missions to the surface of Mars.) However, the “stack controllability” issue poses a serious constraint to hosting large Mars transit vehicles. Moreover, the planned 15-year lifetime of the Gateway may not be long enough to sustain Mars missions.

“The Gateway could have exceeded its planned 15-year on-orbit life as early as 2042 when crewed missions to Mars are potentially just beginning,” the report states.

All in all, the report seems to suggest that the Gateway is way behind schedule and is of limited use to lunar and Mars landings. The report suggests the Gateway will be complex to undertake at the very same time NASA is attempting to establish a lunar surface program. But other than that, everything is going great.

NASA’s Lunar Gateway has a big visiting vehicles problem Read More »

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Boeing’s Starliner has cost at least twice as much as SpaceX’s Crew Dragon

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$$$ —

“Risk remains that we may record additional losses in future periods.”

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A Starliner spacecraft departs Boeing's spacecraft processing facility before the program's first orbital test flight in 2019.

Enlarge / A Starliner spacecraft departs Boeing’s spacecraft processing facility before the program’s first orbital test flight in 2019.

Boeing announced another financial charge Wednesday for its troubled Starliner commercial crew program, bringing the company’s total losses on Starliner to $1.6 billion.

In its quarterly earnings report, Boeing registered a $125 million loss on the Starliner program, blaming delays on the spacecraft’s still-ongoing Crew Flight Test, the program’s first mission to carry astronauts into orbit. This is not the first time Boeing has reported a financial loss on Starliner. Including the new charge announced Wednesday, Boeing has now suffered an overall loss on the program of nearly $1.6 billion since 2016.

These losses have generally been caused by schedule delays and additional work to solve problems on Starliner. When NASA awarded Boeing a $4.2 billion contract to complete development of the Starliner spacecraft a decade ago, the aerospace contractor projected the capsule would be ready to fly astronauts by the end of 2017.

It turns out the Crew Flight Test didn’t launch until June 5, 2024.

In a separate announcement Wednesday, Boeing named Kelly Ortberg as the company’s CEO, effective August 8. He will replace Dave Calhoun, whose tenure as Boeing’s chief executive was marred by scandals with the 737 MAX passenger airplane. Ortberg was previously CEO of Rockwell Collins, now known as Collins Aerospace, a major supplier of avionics and other parts for the aerospace industry.

Boeing is on the hook

When NASA selected Boeing and SpaceX to develop the Starliner and Crew Dragon spacecraft for astronaut missions, the agency signed fixed-price agreements with each contractor. These fixed-price contracts mean the contractors, not the government, are responsible for paying for cost overruns.

So, with each Starliner delay since 2016, Boeing’s financial statements registered new losses. It will be Boeing’s burden to pay for solutions to problems discovered on Starliner’s ongoing crew test flight. That’s why Boeing warned investors Wednesday that it could lose more money on the Starliner program in the coming months and years.

“Risk remains that we may record additional losses in future periods,” Boeing wrote in an SEC filing.

Taking into account the financial loss revealed Wednesday, NASA and Boeing have committed at least $6.7 billion to the Starliner program since 2010, including expenses for spacecraft development, testing, and the government’s payment for six operational crew flights with Starliner.

It’s instructive to compare these costs with those of SpaceX’s Crew Dragon program, which started flying astronauts in 2020. All of NASA’s contracts with SpaceX for a similar scope of work on the Crew Dragon program totaled more than $3.1 billion, but any expenses paid by SpaceX are unknown because it is a privately held company.

SpaceX has completed all six of its original crew flights for NASA, while Boeing is at least a year away from starting operational service with Starliner. In light of Boeing’s delays, NASA extended SpaceX’s commercial crew contract to cover eight additional round-trip flights to the space station through the end of the 2020s.

Boeing’s leaders blame the structure of fixed-price contracts for the losses on the Starliner program. The aerospace giant has similar fixed-price contracts with the Pentagon to develop new two new Air Force One presidential transport aircraft, Air Force refueling tankers, refueling drones, and trainer airplanes. Boeing has reported losses on those programs, too.

SpaceX, meanwhile, has excelled with fixed-price contracts, which NASA uses on several elements of the Artemis program aiming to land astronauts on the Moon. For example, NASA selected SpaceX and Blue Origin, Jeff Bezos’s space company, for fixed-price contracts to develop human-rated lunar landers. SpaceX also won a fixed-price contract to provide NASA with a vehicle to deorbit the International Space Station at the end of its life.

Decision time

The first crew mission aboard Boeing’s Starliner spacecraft is expected to end sometime in August with the return of NASA astronauts Butch Wilmore and Suni Williams from the International Space Station. A successful conclusion of the test flight would pave the way for Boeing to start launching its backlog of six operational crew missions to the space station.

But it hasn’t been that simple. The Starliner test flight was initially expected to stay at the space station for at least eight days. Before the launch in June, NASA and Boeing officials left open the possibility for a mission extension, but managers didn’t anticipate Starliner to still be docked at the space station more than 50 days later.

Mission managers ordered Starliner to stay at the station through the rest of June and July while engineers investigated problems in the spacecraft’s propulsion system. There are helium leaks in Starliner’s service module, and the craft’s small maneuvering thrusters overheated during the final approach for docking at the space station.

NASA, which oversees Boeing’s commercial crew contract, is getting close to clearing Starliner for return to Earth, perhaps as soon as next week. On Saturday, ground controllers commanded Starliner to test-fire its maneuvering thrusters, and 27 of the 28 jets appeared to function normally despite overheating earlier in the mission. Despite the leaks, the spacecraft also has ample helium to pressurize its propulsion system, NASA officials said.

Before giving final approval for Starliner to undock from the space station and return to Earth, senior NASA leaders will convene a readiness review to go over the results of the investigation into the propulsion issues.

Boeing has some work to do to find a long-term fix for the helium leaks and overheating thrusters on future Starliner missions. NASA officials hoped a flawless Starliner test flight would allow the agency to formally certify the capsule for regular six-month expeditions to the space station by the end of the year, allowing Boeing to launch the first operational Starliner flight, known as Starliner-1, in February 2025.

Last week, NASA announced a six-month delay for the Starliner-1 mission to allow more time to solve the problems the spacecraft experienced on the crew test flight.

Boeing’s Starliner has cost at least twice as much as SpaceX’s Crew Dragon Read More »

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With a landmark launch, the Pentagon is finally free of Russian rocket engines

atlas v, cape canaveral, launch, military space, rd-180, russia, Science, Space, space force, united launch alliance, US Space Force, ussf-51 / /
Liftoff of ULA's Atlas V rocket on the US Space Force's USSF-51 mission.

Enlarge / Liftoff of ULA’s Atlas V rocket on the US Space Force’s USSF-51 mission.

United Launch Alliance delivered a classified US military payload to orbit Tuesday for the last time with an Atlas V rocket, ending the Pentagon’s use of Russian rocket engines as national security missions transition to all-American launchers.

The Atlas V rocket lifted off from Cape Canaveral Space Force Station in Florida at 6: 45 am EDT (10: 45 UTC) Tuesday, propelled by a Russian-made RD-180 engine and five strap-on solid-fueled boosters in its most powerful configuration. This was the 101st launch of an Atlas V rocket since its debut in 2002, and the 58th and final Atlas V mission with a US national security payload since 2007.

The US Space Force’s Space Systems Command confirmed a successful conclusion to the mission, code-named USSF-51, on Tuesday afternoon. The rocket’s Centaur upper stage released the top secret USSF-51 payload about seven hours after liftoff, likely in a high-altitude geostationary orbit over the equator. The military did not publicize the exact specifications of the rocket’s target orbit.

“What a fantastic launch and a fitting conclusion for our last national security space Atlas V (launch),” said Walt Lauderdale, USSF-51 mission director at Space Systems Command, in a post-launch press release. “When we look back at how well Atlas V met our needs since our first launch in 2007, it illustrates the hard work and dedication from our nation’s industrial base. Together, we made it happen, and because of teams like this, we have the most successful and thriving launch industry in the world, bar none.”

RD-180’s long goodbye

The launch Tuesday morning was the end of an era born in the 1990s when US government policy allowed Lockheed Martin, the original developer of the Atlas V, to use Russian rocket engines during its first stage. There was a widespread sentiment in the first decade after the fall of the Soviet Union that the United States and other Western nations should partner with Russia to keep the country’s aerospace workers employed and prevent “rogue states” like Iran or North Korea from hiring them.

At the time, the Pentagon was procuring new rockets to replace legacy versions of the Atlas, Delta, and Titan rocket families, which had been in service since the late 1950s or early 1960s.

A cluster of solid rocket boosters surround the RD-180 main engine as the Atlas V launcher climbs away from Cape Canaveral Space Force Station to begin the USSF-51 mission.

Enlarge / A cluster of solid rocket boosters surround the RD-180 main engine as the Atlas V launcher climbs away from Cape Canaveral Space Force Station to begin the USSF-51 mission.

Ultimately, the Air Force chose Lockheed Martin’s Atlas V and Boeing’s Delta IV rocket for development in 1998. The Atlas V, with its Russian main engine, was somewhat less expensive than the Delta IV and the more successful of the two designs. After Tuesday’s launch, 15 more Atlas V rockets are booked to fly payloads for commercial customers and NASA, mainly for Amazon’s Kuiper network and Boeing’s Starliner crew spacecraft. The 45th and final Delta IV launch occurred in April.

Boeing and Lockheed Martin merged their rocket divisions in 2006 to form a 50-50 joint venture named United Launch Alliance, which became the sole contractor certified to carry large US military satellites to orbit until SpaceX started launching national security missions in 2018.

SpaceX filed a lawsuit in 2014 to protest the Air Force’s decision to award ULA a multibillion-dollar sole-source contract for 36 Atlas V and Delta IV rocket booster cores. The litigation started soon after Russia’s military occupation and annexation of Crimea, which prompted US government sanctions on prominent Russian government officials, including Dmitry Rogozin, then Russia’s deputy prime minister and later the head of Russia’s space agency.

Rogozin, known for his bellicose but usually toothless rhetoric, threatened to halt exports of RD-180 engines for US military missions on the Atlas V. That didn’t happen until Russia finally stopped engine exports to the United States in 2022, following its full-scale invasion of Ukraine. At that point, ULA already had all the engines it needed to fly out all of its remaining Atlas V rockets. This export ban had a larger effect on Northrop Grumman’s Antares rocket, which also used Russian engines, forcing the development of a brand new first stage booster with US engines.

The SpaceX lawsuit, Russia’s initial military incursions into Ukraine in 2014, and the resulting sanctions marked the beginning of the end for the Atlas V rocket and ULA’s use of the Russian RD-180 engine. The dual-nozzle RD-180, made by a Russian company named NPO Energomash, consumes kerosene and liquid oxygen propellants and generates 860,000 pounds of thrust at full throttle.

With a landmark launch, the Pentagon is finally free of Russian rocket engines Read More »

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SpaceX moving Dragon splashdowns to Pacific to solve falling debris problem

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A Crew Dragon spacecraft is seen docked at the International Space Station in 2022. The section of the spacecraft on the left is the pressurized capsule, while the rear section, at right, is the trunk.

Enlarge / A Crew Dragon spacecraft is seen docked at the International Space Station in 2022. The section of the spacecraft on the left is the pressurized capsule, while the rear section, at right, is the trunk.

NASA

Sometime next year, SpaceX will begin returning its Dragon crew and cargo capsules to splashdowns in the Pacific Ocean and end recoveries of the spacecraft off the coast of Florida.

This will allow SpaceX to make changes to the way it brings Dragons back to Earth and eliminate the risk, however tiny, that a piece of debris from the ship’s trunk section might fall on someone and cause damage, injury, or death.

“After five years of splashing down off the coast of Florida, we’ve decided to shift Dragon recovery operations back to the West Coast,” said Sarah Walker, SpaceX’s director of Dragon mission management.

Public safety

In the past couple of years, landowners have discovered debris from several Dragon missions on their property, and the fragments all came from the spacecraft’s trunk, an unpressurized section mounted behind the capsule as it carries astronauts or cargo on flights to and from the International Space Station.

SpaceX returned its first 21 Dragon cargo missions to splashdowns in the Pacific Ocean southwest of Los Angeles. When an upgraded human-rated version of Dragon started flying in 2019, SpaceX moved splashdowns to the Atlantic Ocean and the Gulf of Mexico to be closer to the company’s refurbishment and launch facilities at Cape Canaveral, Florida. The benefits of landing near Florida included a faster handover of astronauts and time-sensitive cargo back to NASA and shorter turnaround times between missions.

The old version of Dragon, known as Dragon 1, separated its trunk after the deorbit burn, allowing the trunk to fall into the Pacific. With the new version of Dragon, called Dragon 2, SpaceX changed the reentry profile to jettison the trunk before the deorbit burn. This meant that the trunk remained in orbit after each Dragon mission, while the capsule reentered the atmosphere on a guided trajectory. The trunk, which is made of composite materials and lacks a propulsion system, usually takes a few weeks or a few months to fall back into the atmosphere and doesn’t have control of where or when it reenters.

Air resistance from the rarefied upper atmosphere gradually slows the trunk’s velocity enough to drop it out of orbit, and the amount of aerodynamic drag the trunk sees is largely determined by fluctuations in solar activity.

SpaceX and NASA, which funded a large portion of the Dragon spacecraft’s development, initially determined the trunk would entirely burn up when it reentered the atmosphere and would pose no threat of surviving reentry and causing injuries or damaging property. However, that turned out to not be the case.

In May, a 90-pound chunk of a SpaceX Dragon spacecraft that departed the International Space Station fell on the property of a “glamping” resort in North Carolina. At the same time, a homeowner in a nearby town found a smaller piece of material that also appeared to be from the same Dragon mission.

These events followed the discovery in April of another nearly 90-pound piece of debris from a Dragon capsule on a farm in the Canadian province of Saskatchewan. SpaceX and NASA later determined the debris fell from orbit in February, and earlier this month, SpaceX employees came to the farm to retrieve the wreckage, according to CBC.

Pieces of a Dragon spacecraft also fell over Colorado last year, and a farmer in Australia found debris from a Dragon capsule on his land in 2022.

SpaceX moving Dragon splashdowns to Pacific to solve falling debris problem Read More »

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Although it’s not final, SpaceX just got good news from the FAA on Starbase

FAA, Science, Space, spacex, Starbase, starship / /

A superfluity of Starships —

“SpaceX has dramatically reduced the duration of operations.”

–

The Super Heavy booster for Flight 5 of Starship undergoes a static fire test earlier this month.

Enlarge / The Super Heavy booster for Flight 5 of Starship undergoes a static fire test earlier this month.

SpaceX

After SpaceX decided to launch orbital missions of its Starship rocket from Texas about five years ago, the company had to undergo a federal environmental review of the site to ensure it was safe to do so.

As a part of this multi-year process, the Federal Aviation Administration completed a Final Programmatic Environmental Assessment in June 2022. Following that review, SpaceX received approval to conduct up to five Starship launches from South Texas annually.

SpaceX has since launched Starship four times from its launch site in South Texas, known as Starbase, and is planning a fifth launch within the next two months. However, as it continues to test Starship and make plans for regular flights, SpaceX will need a higher flight rate. This is especially true as the company is unlikely to activate additional launch pads for Starship in Florida until at least 2026.

To that end, SpaceX has asked the FAA for permission for up to 25 flights a year from South Texas, as well as the capability to land both the Starship upper stage and Super Heavy booster stage back at the launch site. On Monday, the FAA signaled that it is inclined to grant permission for this.

A solid step for SpaceX

The federal agency released a 154-page “Draft Tiered Environmental Assessment” for an increased cadence of Starship launches from South Texas. In conclusion, the document stated: “The FAA has concluded that the modification of SpaceX’s existing vehicle operator license for Starship/Super Heavy operations conforms to the prior environmental documentation, consistent with the data contained in the 2022 PEA, that there are no significant environmental changes, and all pertinent conditions and requirements of the prior approval have been met or will be met in the current action.”

Effectively, then, the FAA is saying that its extensive 2022 analysis of Starship activities on the environment, wildlife, local communities, and more was sufficient to account for SpaceX’s proposed modifications.

This is not the final word. In the parlance of the FAA, this is just milestone No. 3 in the seven-part process that results in a final determination. Up next are a series of public meetings, both in person in South Texas and online, during the month of August. The public comment period will then close on August 29.

Although the process is not yet complete, this document indicates the current thinking of federal regulators, who appear inclined to be permissive of an increased scope of activities. This is no small finding, as SpaceX is not only seeking to launch more rockets, but also to land them back at Starbase, as well as significantly increase the thrust of the vehicles.

SpaceX asked the FAA—which has federal authority to regulate such activities in order to protect life and property on the ground—for 25 annual launches and 50 total landings, 25 for Starship and 25 for Super Heavy. The company is also seeking to conduct up to 90 seconds of daytime Starship static fire tests, and 70 seconds of daytime Super Heavy static fire tests a year.

Bigger rockets, more propellant

SpaceX also is developing more powerful variants of its rocket, and the launch of these vehicles would also be permitted. Under the environmental assessment completed in 2022, SpaceX’s plans called for a 50-meter-tall Starship and a 71-meter-tall Super Heavy booster stage. Its upgraded Starship would be 70 meters tall, atop an 80-meter boost stage, for a total stack height of 150 meters.

The company is contemplating a far greater thrust for each of the vehicles, more than doubling Starship’s thrust to 6.5 million pounds and substantially increasing Super Heavy’s thrust to 2.3 million pounds. A bigger, more powerful launch system will require more than 1,500 tons of liquid oxygen and methane propellant.

Upgrade plans for Starship and Super Heavy.

Enlarge / Upgrade plans for Starship and Super Heavy.

FAA

One change that may have helped sell this increased flight rate is that SpaceX is not seeking any additional increases in road closures of State Highway 4, which leads from Brownsville to Boca Chica Beach. This road passes right by the launch site and is closed during launches and static fire tests. SpaceX has moved much of its pre-launch testing to a new location nearby that does not require road closures.

“SpaceX has dramatically reduced the duration of operations and the number of access restrictions through engineering analysis and improvements,” the FAA draft document states. “There has been an 85% reduction in the number of access restrictions from Flight 1 to Flight 3. Additionally, a majority of the testing that required access restrictions has been moved to SpaceX’s Massey’s Test Site, approximately 4 miles away.”

After the public comment period, the FAA will prepare a final environmental assessment and render a decision on the request.

Although it’s not final, SpaceX just got good news from the FAA on Starbase Read More »

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SpaceX roars back to orbit barely two weeks after in-flight anomaly

falcon 9, Science, Space, spacex / /

Look who’s back, back again —

“It was incredible to see how quickly the team was able to identify the cause of the mishap.”

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The Starlink 10-9 mission lifts off early Saturday morning from Florida.

Enlarge / The Starlink 10-9 mission lifts off early Saturday morning from Florida.

SpaceX webcast

Early on Saturday morning, at 1: 45 am local time, a Falcon 9 rocket soared into orbit from its launch site at Kennedy Space Center in Florida.

By some measures this was an extremely routine mission—it was, after all, SpaceX’s 73rd launch of this calendar year. And like many other Falcon 9 launches this year, the “Starlink 10-9” mission carried 23 of the broadband internet satellites into orbit. However, after a rare failure earlier this month, this particular Falcon 9 rocket was making a return-to-flight for the company, and attempting to get the world’s most active booster back into service.

And by all measures, it performed. The first stage booster, B-1069, made its 17th flight into orbit before landing on the Just Read the Instructions drone ship in the Atlantic Ocean. Then, a little more than an hour after liftoff, the rocket’s second stage released its payload into a good orbit, from which the Starlink spacecraft will use their on-board thrusters to reach operational altitudes in the coming weeks.

A crack in the sense line

The Falcon 9 rocket only failed a little more than 15 days ago, during a Starlink launch from Vandenberg Space Force Base, California, at 7: 35 pm PDT (02: 35 UTC) on July 11. During that mission, just a few minutes after stage separation, an unusual buildup of ice was observed on the Merlin vacuum engine that powers the second stage of the vehicle.

According to the company, the Merlin vacuum engine successfully completed its first burn after the second stage separated. However, during this time a liquid oxygen leak developed near the engine—which led to the buildup of ice observed during the webcast.

Engineers and technicians were quickly able to pinpoint the cause of the leak, a crack in a “sense line” for a pressure sensor attached to the vehicle’s liquid oxygen system. “This line cracked due to fatigue caused by high loading from engine vibration and looseness in the clamp that normally constrains the line,” the company said in an update published prior to Saturday morning’s launch.

This leak excessively cooled the engine, and caused a lower amount of igniter fluid to be available prior to re-lighting the Merlin for its second burn to circularize the rocket’s orbit before releasing the Starlink satellites. This caused a hard start of the Merlin engine. Ultimately the satellites were released into a lower orbit, where they burnt up in Earth’s atmosphere within days.

The sense line that failed is redundant, SpaceX said. It is not used by the flight safety system, and can be covered by alternate sensors already present on the engine. In the near term, the sense line will be removed from the second stage engine for Falcon 9 launches.

During a news briefing Thursday, SpaceX director Sarah Walker said this sense line was installed based on a customer requirement for another mission. The only difference between this component and other commonly flown sense lines is that it has two connections rather than one, she said. This may have made it a bit more susceptible to vibration, leading to a small crack.

Getting back fast

SpaceX identified the cause of the failure within hours of the anomaly, and worked the Federal Aviation Administration to come to a rapid resolution. On Thursday, the launch company received permission to return to flight.

“It was incredible to see how quickly the team was able to identify the cause of the mishap, and then the associated corrective actions to ensure success,” Walker said.

Before the failure on the night of July 11th, SpaceX had not experienced a mission failure in the previous 297 launches of the Falcon 9 rocket, dating back to the Amos-6 launch pad explosion in September 2016. The short interval between the failure earlier this month, and Saturday’s return to flight, appears to be unprecedented in spaceflight history.

The company now plans to launch two more Starlink missions on the Falcon 9 rocket this weekend, one from Cape Canaveral Space Force Station in Florida, as well as Vandenberg Space Force Base in California. It then has three additional missions before a critical astronaut flight for NASA, Crew-9, that could occur as soon as August 18.

For this reason, NASA was involved in the investigation of the second stage failure. Steve Stich, manager of NASA’s Commercial Crew Program, said SpaceX did an “extraordinary job” in identifying the root cause of the failure, and then rapidly looking at its Dragon spacecraft and first stage of the Falcon 9 rocket to ensure there were no other sensors that could cause similar problems.

SpaceX roars back to orbit barely two weeks after in-flight anomaly Read More »