Enlarge/ An H-IIA rocket lifts off with the IGS Optical-8 spy satellite.
Mitsubishi Heavy Industries
Welcome to Edition 6.27 of the Rocket Report! This week, we discuss an intriguing new report looking at Starship. Most fascinating, the report covers SpaceX’s costs to build a Starship and how these costs will come down as the company ramps up its build and launch cadence. At the other end of the spectrum, former NASA Administrator Mike Griffin has a plan to get astronauts back to the Moon that would wholly ignore the opportunities afforded by Starship.
As always, we welcome reader submissions, and 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.
The problem at America’s military spaceports. The Biden administration is requesting $1.3 billion over the next five years to revamp infrastructure at the Space Force’s ranges in Florida and California, Ars reports. This will help address things like roads, bridges, utilities, and airfields that, in many cases, haven’t seen an update in decades. But it’s not enough, according to the Space Force. Last year, Cape Canaveral was the departure point for 72 orbital rocket launches, and officials anticipate more than 100 this year. The infrastructure and workforce at the Florida spaceport could support about 150 launches in a year without any major changes, but launch activity is likely to exceed that number within a few years.
Higher fees incoming … Commercial launch companies operating from Cape Canaveral Space Force Station, Florida, or Vandenberg Space Force Base, California, pay fees to the Space Force to reimburse for direct costs related to rocket launches. These cover expenses like weather forecast services, surveillance to ensure airplanes and boats stay out of restricted areas, and range safety support. “What that typically meant was anything we did that was specifically dedicated to that launch,” said Col. James Horne, deputy commander of the Space Force’s assured access to space directorate. This is about to change after legislation passed by Congress in December allows the Space Force to charge indirect fees to commercial providers. This money will go into a fund to pay for maintenance and upgrades to infrastructure used by all launch companies at the spaceports.
Momentus is running out of money. Momentus, a company that specializes in “last mile” satellite delivery services, announced on January 12 that it is running out of money and does not have a financial lifeline, CNBC reports. The company was once valued at more than $1 billion before going public via a Special Purpose Acquisition Company (SPAC) in 2021 but now has a market capitalization of less than $10 million. Momentus has developed a space tug called Vigoride, designed to place small satellites into bespoke orbits after deploying from a larger rocket on a rideshare mission, such as a SpaceX Falcon 9. Now, Momentus is abandoning plans for its next mission that was due for launch in March. In December, the company laid off about 20 percent of its workforce to reduce costs.
Fatal blow? … Momentus may have received a potentially fatal blow after losing the US Space Development Agency’s recent competition for 18 so-called Tranche 2 satellites, Aviation Week reports. Instead, the SDA made recent satellite manufacturing contract awards to Rocket Lab, L3Harris, Lockheed Martin, and Sierra Space. On Wednesday, Momentus announced it closed a $4 million stock sale. This should keep Momentus afloat for a while longer but won’t provide the level of capital needed to undertake any significant manufacturing or technical development work. (submitted by Ken the Bin)
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Orbex may go bigger. UK-based launch startup Orbex hasn’t yet flown its small satellite launcher, called Prime, but is already looking at what’s next, according to reports by European Spaceflight and the Financial Times. New Orbex CEO Phil Chambers, who was officially appointed earlier this month, told the Financial Times that the company was already discussing the possibility of developing a larger vehicle. Speaking to European Spaceflight, Chambers described the business model to deliver orbital launch services with Prime as “robust.” Despite this, he admitted that the small launch industry was only a small sliver of the overall launch market.
Learning to walk before running … While future growth is on Orbex’s radar, its near-term focus is completing construction of a spaceport in Scotland, launching a maiden flight of Prime, and delivering on the six flights the company has already sold. The two-stage Prime rocket, fueled by “bio-propane,” will be capable of hauling a payload of approximately 180 kilograms (nearly 400 pounds) into low-Earth orbit. But Orbex has been shy about releasing updates on the progress of the Prime rocket’s development since unveiling a full-scale mock-up of the launch vehicle in 2022. Last year, the CEO who led Orbex since its founding resigned. Its most recent significant funding round was valued at 40.4 million pounds in late 2022. (submitted by Ken the Bin)
Enlarge/ A Falcon 9 rocket lifts off from NASA’s Kennedy Space Center to begin the Ax-3 commercial crew mission.
Stephen Clark/Ars Technica
For the third time, an all-private crew is heading for the International Space Station. The four-man team lifted off from NASA’s Kennedy Space Center in Florida aboard a SpaceX Falcon 9 rocket Thursday, kicking off a 36-hour pursuit of the orbiting research laboratory. Docking is scheduled for Saturday morning.
This two-week mission is managed by Houston-based Axiom Space, which is conducting private astronaut missions to the ISS as a stepping stone toward building a fully commercial space station in low-Earth orbit by the end of this decade.
Axiom’s third mission, called Ax-3, launched at 4: 49 pm EST (21: 49 UTC) Thursday. The four astronauts were strapped into their seats inside SpaceX’s Dragon Freedom spacecraft atop the Falcon 9 rocket. This is the 12th time SpaceX has launched a human spaceflight mission, and could be the first of five Dragon crew missions this year.
The Falcon 9 steered northeast from the Kennedy Space Center to line up with the flight track of the International Space Station. After darting through cloud cover, the rocket’s reusable first stage detached two-and-a-half minutes after liftoff to begin a descent back to Cape Canaveral for landing. The upper stage ignited a single engine to carry the Dragon capsule into orbit.
No retirement party
In remarks radioed to the ground soon after the launch, Ax-3 commander Michael López-Alegría describe the sensations of launch as “acceleration, a little bit of vibration, just a sense that you’re going fast. Wow, what a thrill!”
López-Alegría is a Spanish-born astronaut and US Navy veteran. He is one of the most experienced astronauts in history, and Ax-3 marks his sixth flight to space. López-Alegría, 65, retired from NASA in 2012 after four space shuttle missions. He worked as a consultant and commercial spaceflight advocate, then joined Axiom in 2017, and commanded the company’s first private astronaut flight in 2022.
So why keep up a grueling training schedule at an age when most commercial airline pilots face mandated retirement?
“It never gets old,” López-Alegría said in a prelaunch press conference. “I think I have more appreciation with every launch that approaches … The first time you go, you’re just hanging on for dear life and and enjoying the ride. But I think you appreciate each one a little bit more, especially when you realize just how rare and opportunity it is, so I’m happy to keep doing this.”
He is alternating commands of Axiom missions with Peggy Whitson, another retired NASA astronaut.
“Axiom would definitely like to continue doing private astronaut missions. We’ll probably have other commanders in the future, but as long as they ask me to fly, my hand will be raised,” López-Alegría said. He’s the first astronaut to fly on SpaceX’s Dragon spacecraft twice.
“I think you’re demonstrating the ultimate in reuse—a reused commander, a reused Dragon, and a reused Falcon, or maybe flight-experienced is a better word,” joked Bill Gerstenmaier, a SpaceX executive serving as chief engineer for Thursday’s launch.
Pilot Walter Villadei sat to López-Alegría’s right during the climb into orbit. He is a colonel in the Italian Air Force. Turkey’s first astronaut, Alper Gezeravcı, and Swedish test pilot pilot Marcus Wandt round out the Ax-3 crew. They will temporarily join the long-duration residents living on the space station, including four crew members who flew on a Dragon to the complex in August to begin a six-month stay.
Cornering the government market
Villadei, Gezeravcı, and Wandt are flying to the space station through contracts between their governments and Axiom. The astronauts, all military officers, will perform scientific experiments developed by their nation’s researchers, and participate in education and outreach events from orbit.
More than 30 research investigations are flying on Ax-3, ranging from biology physiology experiments looking at how microgravity affects the human body, to technology demonstrations and Earth science. For example, the Italian Air Force developed a software tool it will test on Ax-3 to provide space debris and space weather warnings to the space station. Turkey is sending up experiments in the fields of genetics and metallurgy. Sweden and the European Space Agency sponsor experiments in brain research, remote control and AI, and stem cells.
Enlarge/ Michael López-Alegría, Alper Gezeravcı, Marcus Wandt, and Walter Villadei pose inside SpaceX’s crew access arm at Launch Complex 39A in Florida.
SpaceX
But there’s an unmistakable element of national pride intertwined with these scientific objectives.
Villadei is flying under the Italian flag through an agreement between the Italian government and Axiom, whereas most Italian astronauts have historically flown under the umbrella of the European Space Agency. He previously soared into space on a suborbital flight on Virgin Galactic’s spaceplane, logging a few minutes of microgravity. He was one of three Italian Air Force service members on the Virgin Galactic flight last June.
“This mission is very important for Italy,” Villadei said. “It’s a fundamental step in our national space strategy.”
Gezeravcı’s flight is historic in the sense that he is the first Turkish citizen to travel into space. “We have been long waiting for this mission to become real,” he said. “I’m really honored to take this role in this mission and to be able to make it real.”
Wandt’s mission was made possible through an agreement between ESA and the Swedish National Space Agency. ESA then finalized an agreement with Axiom to secure Wandt’s seat on Ax-3.
Wandt’s presence on the crew marks a first for ESA. It’s the first time the space agency has flown one of its astronauts to orbit with a commercial company, rather than an intergovernmental agreement with the United States or Russia. He was one of 17 astronauts ESA selected in 2022, but he joined ESA’s ranks as a reserve astronaut, meaning he would continue his career as a test pilot at Saab Aeronautics until his selection for a space mission.
He didn’t have to wait long. “This additional flight came up and Sweden was very decisive in this and came together quickly with industry, the armed forces, government, and together with ESA made this happen together with Axiom,” Wandt said.
ESA has six active astronauts who have flown in space, plus five new career astronauts and 12 reserves selected in 2022. Commercial flight opportunities like this one with Axiom enable more Europeans to access space. An ESA reserve astronaut from Poland could launch on an Axiom mission later this year.
“We have our astronaut corps, who represent the spine of our activities in human spaceflight,” said Daniel Neuenschwander, ESA’s director of human and robotic exploration, in an interview with Ars on Thursday. “But we selected also these reserves, which is a kind of pool of talent, where we seize the opportunities which come on top. It allows us to do more activities in human spaceflight.”
Axiom doesn’t publicize seat prices for its missions to the space station, but in the past, they have reportedly cost around $55 million. Swedish media last year reported Sweden expanded its investment in ESA by more than 400 million Swedish krona, or more than $38 million at current exchange rates, to enable Wandt’s spaceflight opportunity.
Axiom officials view flying government-backed astronauts as a lucrative market. It’s distinct from the conventional image of wealthy space tourists who pay their own way into orbit. There is, of course, an element of that in Axiom’s business, too. Axiom’s first mission in 2022 flew three self-paying private astronauts, and Ax-2 last year flew a mixed crew consisting of an Axiom commander, a US businessman, and two Saudi astronauts flying on a government-sponsored mission.
NASA is also supporting these private astronaut missions. The US space agency opened up the International Space Station to private visitors flying on all-commercial missions in 2019. It’s a cornerstone of NASA’s strategy to foster a commercial market for human spaceflight in low-Earth orbit, with an eye toward eventually building a business case for a privately-owned space station to replace the ISS after its planned retirement in 2030.
Enlarge/ The Morrell Operations Center at Cape Canaveral Space Force Station, Florida.
A lot goes into a successful rocket launch. It’s not just reliable engines, computers, and sophisticated guidance algorithms. There’s also the launch pad, and perhaps even more of an afterthought to casual observers, the roads, bridges, pipelines, and electrical infrastructure required to keep a spaceport humming.
Brig. Gen. Kristin Panzenhagen, commander of the Space Force’s Eastern Range at Cape Canaveral Space Force Station in Florida, calls this the “non-sexy stuff that we can’t launch without.” Much of the ground infrastructure at Cape Canaveral and Vandenberg Space Force Base in California, the military’s other launch range, is antiquated and needs upgrades or expansion.
“Things like roads, bridges, even just the entry into the base, the gate, communications infrastructure, power, we’re looking at overhauling and modernizing all of that because we really haven’t done a tech refresh on all of that in a very long time, at least 20 years, if not more,” said Col. James Horne, deputy director for the Space Force’s assured access to space directorate.
Getting a congressional appropriation for new rocket or spacecraft development, research into advanced technology, or military pay raises has generally been easier than securing funds for military construction projects.
“Trying to do all those upgrades on just our annual budget is not possible,” Panzenhagen said earlier his week in a presentation to the National Space Club Florida Committee.
Charging ahead
The Biden administration is requesting $1.3 billion over the next five years to revamp infrastructure at the Space Force’s ranges in Florida and California. According to Panzenhagen, one of the first projects will be an upgrade to the airfield at Cape Canaveral, where the military regularly delivers satellites and other equipment to the launch site.
But this funding won’t be enough for Cape Canaveral and Vandenberg to meet the Space Force’s projected launch demand fully. Last year, there were 72 orbital launch attempts from Florida and 30 launches from California.
“I would anticipate we’re going to do over 100 launches from the Cape this year,” Panzenhagen said. “And that puts a strain on a lot of our workforce, so we are doing process things to try to operate more smartly.”
Enlarge/ This long exposure photo shows a SpaceX Falcon Heavy rocket streaking into space from NASA’s Kennedy Space Center in Florida. A few minutes later, the rocket’s side boosters returned to land at Cape Canaveral Space Force Station a few miles away.
There has been a significant uptick in launch cadence at Cape Canaveral. In 2008, there were only seven launches from the Florida spaceport. Since SpaceX started launching its Falcon 9 rocket in 2010, the launch cadence in Florida has been on a steady rise.
“This is not a hard limit, but I think at the Cape, we could probably push through somewhere on the order of 150 launches per year if we did nothing,” Horne told Ars in a recent interview. “And then probably 75 or so per year from Vandenberg. Everything we’re doing is continuing to improve that ability so that we’re not in the way. So whenever they say they need to go, we say yes.”
The Space Force provides security, weather forecasting, telemetry, and safety oversight services for all launches from Cape Canaveral and Vandenberg. The launch ranges in Florida and California are primarily responsible for ensuring the US military has an always-on capability to launch critical national security satellites. But the majority of launches from the military ranges are commercial missions.
Enlarge/ Firefly Aerospace’s fourth Alpha rocket lifted off December 22 from Vandenberg Space Force Base, California.
Welcome to Edition 6.25 of the Rocket Report! We hope all our readers had a peaceful holiday break. While many of us were enjoying time off work, launch companies like SpaceX kept up the pace until the final days of 2023. Last year saw a record level of global launch activity, with 223 orbital launch attempts and 212 rockets successfully reaching orbit. Nearly half of these missions were by SpaceX.
As always, we welcome reader submissions, and 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.
Firefly’s fourth launch puts payload in wrong orbit. The fourth flight of Firefly Aerospace’s Alpha rocket on December 22 placed a small Lockheed Martin technology demonstration satellite into a lower-than-planned orbit after lifting off from Vandenberg Space Force Base, California. US military tracking data indicated the Alpha rocket released its payload into an elliptical orbit ranging between 215 and 523 kilometers in altitude, not the mission’s intended circular target orbit. Firefly later confirmed the Alpha rocket’s second stage, which was supposed to reignite about 50 minutes after liftoff, did not deliver Lockheed Martin’s satellite into the proper orbit. This satellite, nicknamed Tantrum, was designed to test Lockheed Martin’s new wideband Electronically Steerable Antenna technology to demonstrate faster on-orbit sensor calibration to deliver rapid capabilities to US military forces.
Throwing a tantrum? … This was the third time in four flights that Firefly’s commercial Alpha rocket, designed to loft payloads up to a metric ton in mass, has not reached its orbital target. The first test flight in 2021 suffered an engine failure on the first stage before losing control shortly after liftoff. The second Alpha launch in 2022 deployed its satellites into a lower-than-planned orbit, leaving them unable to complete their missions. In September, Firefly launched a small US military satellite on a responsive launch demonstration. Firefly and the US Space Force declared that mission fully successful. Atmospheric drag will likely pull Lockheed Martin’s payload back into Earth’s atmosphere for a destructive reentry in a matter of weeks. The good news is ground teams are in contact with the satellite, so there could be a chance to complete at least some of the mission’s objectives. (submitted by Ken the Bin)
Australian startup nears first launch. The first locally made rocket to be launched into space from Australian soil is scheduled for liftoff from a commercial facility in Queensland early next year, the Australian Broadcasting Corporation reports. A company named Gilmour Space says it hopes to launch its first orbital-class Eris rocket in March, pending final approval from Australian regulatory authorities. This would be the first Australian-built orbital rocket, although a US-made rocket launched Australia’s first satellite from a military base in South Australia in 1967. The UK’s Black Arrow rocket also launched a satellite from the same remote Australian military base in 1971.
Getting to know Eris … The three-stage Eris rocket stands 25 meters (82 feet) tall with the ability to deliver up to 300 kilograms (660 pounds) of payload into low-Earth orbit, according to Gilmour Space. The company says the Eris rocket will be powered by Gilmour’s “new and proprietary hybrid rocket engine.” These kinds of propulsion systems use a solid fuel and a liquid oxidizer. We’ll be watching to see if Gilmour shares more tangible news about the progress toward the first Eris launch in March. In late 2022, the company targeted April 2023 for the first Eris flight, so this program has a history of delays. (submitted by Marzipan and Onychomys)
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A commander’s lament on the loss of a historic SpaceX booster. The Falcon 9 rocket that launched NASA astronauts Doug Hurley and Bob Behnken on SpaceX’s first crew mission in 2020 launched and landed for the 19th and final time just before Christmas, then tipped over on its recovery ship during the trip back to Cape Canaveral, Florida, Ars reports. This particular booster, known by the tail number B1058, was special among SpaceX’s fleet of reusable rockets. It was the fleet leader, having tallied 19 missions over the course of more than three-and-a-half years. More importantly, it was the rocket that thundered into space on May 30, 2020, on a flight that made history.
A museum piece? … The lower third of the booster was still on the deck of SpaceX’s recovery ship as it sailed into Port Canaveral on December 26. This portion of the rocket contains the nine Merlin engines and landing legs, some of which appeared mangled after the booster tipped over in high winds and waves. Hurley, who commanded SpaceX’s Crew Dragon spacecraft on the booster’s historic first flight in 2020, said he hopes to see the remaining parts of the rocket in a museum. “Hopefully they can do something because this is a little bit of an inauspicious way to end its flying career, with half of it down at the bottom of the Atlantic Ocean,” said Hurley.
SpaceX opens 2024 campaign with a new kind of Starlink satellite. SpaceX has launched the first six Starlink satellites that will provide cellular transmissions for customers of T-Mobile and other carriers, Ars reports. A Falcon 9 rocket launched from California on January 2 carried 21 Starlink satellites overall, including the first six Starlinks with Direct to Cell capabilities. SpaceX says these satellites, and thousands of others to follow, will “enable mobile network operators around the world to provide seamless global access to texting, calling, and browsing wherever you may be on land, lakes, or coastal waters without changing hardware or firmware.” T-Mobile said that field testing of Starlink satellites with the T-Mobile network will begin soon. “The enhanced Starlink satellites have an advanced modem that acts as a cellphone tower in space, eliminating dead zones with network integration similar to a standard roaming partner,” SpaceX said.
Two of 144 … SpaceX followed this launch with another Falcon 9 flight from Florida on January 3 carrying a Swedish telecommunications satellite. These were the company’s first two missions of 2024, a year when SpaceX officials aim to launch up to 144 rockets, an average of 12 per month, exceeding the 98 rockets it launched in 2023. A big focus of SpaceX’s 2024 launch manifest will be delivering these Starlink Direct to Cell satellites into orbit. (submitted by Ken the Bin)
Chinese booster lands near homes. China added a new pair of satellites to its Beidou positioning and navigation system on December 25, but spent stages from the launch landed within inhabited areas, Space News reports. Meanwhile, a pair of the side boosters from the Long March 3B rocket used for the launch appeared to fall to the ground near inhabited areas in Guangxi region, downrange of the Xichang spaceport in Sichuan province, according to apparent bystander footage on Chinese social media. One video shows a booster falling within a forested area and exploding, while another shows a falling booster and later, wreckage next to a home.
Life downrange … Chinese government authorities reportedly issue warnings and evacuation notices for citizens living in regions where spent rocket boosters are likely to fall after launch, but these videos clearly show people are still close by as the rockets fall from the sky. We’ve seen this kind of imagery before, including views of a rocket that crashed into a rural building in 2019. What’s more, the rockets return to Earth with leftover toxic propellants—hydrazine and nitrogen tetroxide—that could be deadly to breathe or touch. Clouds of brownish-orange gas are visible around the rocket wreckage, an indication of the presence of nitrogen tetroxide. China built its three Cold War-era spaceports in interior regions to protect them from possible military attacks, while its newest launch site is at a coastal location on Hainan Island, allowing rockets launched there to drop boosters into the sea. (submitted by Ken the Bin and EllPeaTea)
Launch date set for next H3 test flight. The second flight of Japan’s new flagship H3 rocket is scheduled for February 14 (US time; February 15 in Japan), the Japan Aerospace Exploration Agency announced on December 28. This will come nearly one year after the first H3 test flight failed to reach orbit last March when the rocket’s second stage failed to ignite a few minutes after liftoff. This failure destroyed a pricey Japanese Earth observation satellite and dealt a setback to Japan’s rocket program. The H3 is designed to be cheaper and more capable than the H-IIA and H-IIB rockets it will replace. Eventually, the H3 will launch Japan’s scientific research probes, spy satellites, and commercial payloads.
Fixes since the first flight … Engineers narrowed the likely cause for the first H3 launch failure to an electrical issue, although Japanese officials have not provided an update on the investigation for several months. In August, Japan’s space agency said investigators had narrowed the cause of the H3’s second-stage malfunction to three possible failure scenarios. Nevertheless, officials are apparently satisfied the H3 is ready to fly again. But this time, there won’t be an expensive satellite aboard. A dummy payload will fly inside the H3 rocket’s nose cone, along with two relatively low-cost small satellites hitching a piggyback ride to orbit. (submitted by Ken the Bin and EllPeaTea)
India’s PSLV launches first space mission of 2024. The first orbital launch of the new year, as measured in the globally recognized Coordinated Universal Time, or UTC, was the flight of an Indian Polar Satellite Launch Vehicle (PSLV) on January 1 (December 31 in the United States). This launch deployed an X-ray astronomy satellite named XPoSat, which will measure X-ray emissions from black holes, neutron stars, active galactic nuclei, and pulsars. This is India’s first X-ray astronomy satellite, and its launch is another sign of India’s ascendence among the world’s space powers. India has some of the world’s most reliable launch vehicles, is developing a human-rated capsule to carry astronauts into orbit, and landed its first robotic mission on the Moon last year.
Going lower … After releasing the XPoSat payload, the PSLV’s fourth stage lowered its orbit to begin an extended mission hosting 10 scientific and technology demonstration experiments. These payloads will test new radiation shielding technologies, green propulsion, and fuel cells in orbit, according to the Indian Space Research Organization. On missions with excess payload capacity, India has started offering researchers and commercial companies the opportunity to fly experiments on the PSLV fourth stage, which has its own solar power source to essentially turn itself from a rocket into a satellite platform. (submitted by EllPeaTea and Ken the Bin)
Mixed crews will continue flying to the International Space Station. NASA and the Russian space agency, Roscosmos, will extend an agreement on flying each other’s crew members to the International Space Station through 2025, Interfax reports. This means SpaceX’s Crew Dragon spacecraft and Boeing’s Starliner capsule, once operational, will continue transporting Russian cosmonauts to and from the space station, as several recent SpaceX crew missions have done. In exchange, Russia will continue flying US astronauts on Soyuz missions.
There’s a good reason for this… Despite poor relations on Earth, the US and Russian governments continue to be partners on the ISS. While NASA no longer has to pay for seats on Soyuz spacecraft, the US space agency still wants to fly its astronauts on Soyuz to protect against the potential for a failure or lengthy delay with a SpaceX or Boeing crew mission. Such an event could lead to a situation where the space station has no US astronauts aboard. Likewise, Roscosmos benefits from this arrangement to ensure there’s always a Russian on the space station, even in the event of a problem with Soyuz. (submitted by Ken the Bin)
SpaceX sets new records to close out 2023. SpaceX launched two rockets, three hours apart, to wrap up a record-setting 2023 launch campaign, Ars reports. On December 28, SpaceX launched a Falcon Heavy rocket from NASA’s Kennedy Space Center in Florida with the US military’s super-secret X-37B spaceplane. Less than three hours later, a Falcon 9 rocket took off a few miles to the south with another batch of Starlink Internet satellites. These were SpaceX’s final launches of 2023. SpaceX ended the year with 98 flights, including 91 Falcon 9s, five Falcon Heavy rockets, and two test launches of the giant new Super Heavy-Starship rocket. These flights were spread across four launch pads in Florida, California, and Texas. It was also the shortest turnaround between two SpaceX flights in the company’s history, and set a modern-era record at Cape Canaveral, Florida, with the shortest span between two orbital-class launches there since 1966.
Where’s the X-37B?… The military’s reusable X-37B spaceplane that launched on the Falcon Heavy rocket apparently headed into an unusually high orbit, much higher than the spaceplane program’s previous six flights. But the military kept the exact orbit a secret, and amateur skywatchers will be closely watching for signs of the spaceplane passing overhead in hopes of estimating its apogee, perigee, and inclination. What the spaceplane is doing is also largely a mystery. The X-37B 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.
Elon Musk says SpaceX needs to built a lot of Starships. Even with reusability, SpaceX will need to build Starships as often as Boeing builds 737 jetliners in order to realize Elon Musk’s ambition for a Mars settlement, Ars reports. “To achieve Mars colonization in roughly three decades, we need ship production to be 100/year, but ideally rising to 300/year,” Musk wrote on his social media platform X. SpaceX still aims to make the Starship and its Super Heavy booster rapidly reusable. The crux is that the ship, the part that would travel into orbit, and eventually to the Moon or Mars, won’t be reused as often as the booster. These ships will come in a number of different configurations, including crew and cargo transports, refueling ships, fuel depots, and satellite deployers.
Laws of physics… The first stage of the giant launch vehicle, named Super Heavy, is designed to return to SpaceX’s launch sites about six minutes after liftoff, similar to the way SpaceX recovers its Falcon boosters today. Theoretically, Musk wrote, the booster could be ready for another flight in an hour. With the Starship itself, the laws of physics and the realities of geography come into play. As an object flies in low-Earth orbit, the Earth rotates underneath it. This means that a satellite, or Starship, will find itself offset some 22.5 degrees in longitude from its launch site after a single 90-minute orbit around the planet. It could take several hours, or up to a day, for a Starship in low-Earth orbit to line up with one of the recovery sites. “The ship needs to complete at least one orbit, but often several to have the ground track line back up with the launch site, so reuse may only be daily,” Musk wrote. “This means that ship production needs to be roughly an order of magnitude higher than booster production.”
Next three launches
January 5: Kuaizhou 1A | Unknown Payload | Jiuquan Satellite Launch Center, China | 11: 20 UTC
January 7: Falcon 9 | Starlink 6-35 | Cape Canaveral Space Force Station, Florida | 21: 00 UTC
January 8: Falcon 9 | Starlink 7-10 | Vandenberg Space Force Base, California | 05: 00 UTC
Enlarge/ Ship 28, the Starship for SpaceX’s next full-scale test flight, fires up one of its engines on December 29 in Texas.
SpaceX
It’s no secret that Elon Musk has big ambitions for SpaceX’s Starship mega-rocket. This is the vehicle that, with plenty of permutations and upgrades, Musk says will ferry cargo and people across the Solar System to build a settlement on Mars, making humanity a multi-planetary species and achieving the billionaire’s long-standing dream.
Of course, that is a long way off. SpaceX is still working on getting Starship into orbit or close to it, an achievement that appears to be possible this year. Then, the company will start launching Starlink satellites on Starship missions while testing in-space refueling technology needed to turn Starship into a human-rated Moon lander for NASA.
SpaceX’s South Texas team is progressing toward the third full-scale Starship test flight. On December 20, the Starship’s upper stage slated for the next test flight completed a test-firing of its Raptor engines at the Starbase launch site on the Texas Gulf Coast. Nine days later, the 33-engine Super Heavy booster fired up on the launch pad for its own static fire test. On the same day, SpaceX hot-fired the Starship upper stage once again on a test stand next to the launch pad.
With those milestones complete, ground teams rolled the booster back to its hangar for final preflight checks and reconfigurations. The ship, too, will need to be rolled back to its high bay.
SpaceX could be weeks away from having both vehicles ready to fly, but the company hasn’t released an update on lessons learned from the previous Starship test flight in November. That flight was largely successful, with apparently flawless performance from the 33 engines on the Super Heavy booster during launch. The Starship upper stage reached space before self-destructing downrange over the Gulf of Mexico. The booster exploded during a maneuver to bring itself back to Earth for a controlled splashdown at sea.
The company’s engineers will want to understand and correct whatever caused those issues. The Federal Aviation Administration then needs to approve SpaceX’s investigation into the last Starship flight before issuing a new commercial launch license. When it flies again, Starship will try to reach near orbital velocity, enough speed to travel most of the way around the world before reentering the atmosphere near Hawaii.
Verifying the performance of Starship’s heat shield tiles during reentry will be valuable learning for SpaceX, but Starship first needs to be fully successful with a launch. This is just the start for the privately funded Starship program.
Enlarge/ One of the most historic rockets in SpaceX’s fleet toppled over Christmas Day on the return trip to Cape Canaveral, Florida, following its previous mission.
The Falcon 9 rocket that launched NASA astronauts Doug Hurley and Bob Behnken on SpaceX’s first crew mission in 2020 launched and landed for the 19th and final time just before Christmas, then tipped over on its recovery ship during the trip back to Cape Canaveral, Florida.
This particular booster, known by the tail number B1058, was special among SpaceX’s fleet of reusable rockets. It was the fleet leader, having tallied 19 missions over the course of more than three-and-a-half years. More importantly, it was the rocket that thundered into space on May 30, 2020, on a flight that made history on several counts.
It was the first time a commercial rocket and spacecraft launched people into orbit, and ended a nine-year gap in America’s ability to send astronauts into orbit from US soil, following the retirement of the space shuttle. This mission, known as Demo-2 and launched by SpaceX under contract with NASA, ended US reliance on Russian rockets to send crews to the International Space Station.
SpaceX recovered the booster on one of its offshore landing platforms after the historic launch in May 2020, while the Falcon 9’s upper stage fired into orbit with the Crew Dragon spacecraft containing Hurley and Behnken. Then, the rocket went into SpaceX’s fleet rotation to launch 18 more times, primarily on missions to deploy Starlink Internet satellites.
Hurley, who commanded the Crew Dragon spacecraft on the Demo-2 mission, kept up with the booster’s exploits well after his return to Earth. He regularly exchanged text messages with Behnken and Kiko Dontchev, SpaceX’s vice president of launch, as the rocket just kept flying.
“For Bob and I, that particular booster was always pretty special for a lot of reasons,” said Hurley, a veteran Marine Corps fighter pilot who retired from NASA’s astronaut corps in 2021. He now works at Northrop Grumman.
An inauspicious ending
Hurley told Ars he would like to see the booster’s remains displayed in a museum alongside the Crew Dragon spacecraft (named Endeavour) he and Behnken flew in 2020. “In a perfect world, I’d love to see Endeavour and at least now part of that booster in the Smithsonian or in a museum somewhere,” he said.
“It’s kind of a bummer,” Hurley told Ars. But he understands SpaceX got a lot of use out of this rocket. SpaceX also has a lot of love for Hurley and Behnken. The company named two of its recovery ships for payload fairings “Bob” and “Doug” after the astronaut duo.
“SpaceX has got a business to run,” he said. “I think, at this point, certainly Endeavour is going to fly more, but this booster isn’t, so hopefully they can find a spot to display it somewhere. Even part of it would look kind of cool somewhere. They could figure something out … People, I think, can get a lot of inspiration from seeing stuff that’s actually flown in space, and being able to get right up close to it, I think, is a big deal to a lot of people.”
Enlarge/ Doug Hurley, right, commanded the Crew Dragon spacecraft on the Demo-2 mission in 2020.
NASA
The 19th launch of this booster on December 23 was just as successful as the previous 18, with a smooth climb into space before shutting down its nine kerosene-fueled Merlin engines. The booster coasted to the highest point in its trajectory—72 miles (116 kilometers)—before Earth’s gravity pulled it back into the atmosphere.
Two engine burns slowed the rocket as it descended toward SpaceX’s drone ship positioned near the Bahamas, and then four carbon-fiber legs deployed moments before an on-target touchdown. Then, as usual, the recovery vessel started its slow journey back to Florida with the 15-story-tall booster standing vertically.
Enlarge/ SpaceX’s Falcon Heavy rocket lifted off Thursday night from NASA’s Kennedy Space Center in Florida.
It seems like SpaceX did everything this year but launch 100 times.
On Thursday night, the launch company sent two more rockets into orbit from Florida. One was a Falcon Heavy, the world’s most powerful rocket in commercial service, carrying the US military’s X-37B spaceplane from a launch pad at NASA’s Kennedy Space Center at 8: 07 pm EST (01: 07 UTC). Less than three hours later, at 11: 01 pm EST (04: 01 UTC), SpaceX’s workhorse Falcon 9 launcher took off a few miles to the south with a payload of 23 Starlink Internet satellites.
The Falcon Heavy’s two side boosters and the Falcon 9’s first stage landed back on Earth for reuse.
These were SpaceX’s final launches of 2023. SpaceX ends the year with 98 flights, including 91 Falcon 9s, five Falcon Heavy rockets, and two test launches of the giant new Super Heavy-Starship rocket. These flights were spread across four launch pads in Florida, California, and Texas.
Elon Musk, SpaceX’s founder and CEO, set a goal of 100 launches this year, up from the company’s previous record of 61 in 2022. For a while, it looked like SpaceX was on track to accomplish the feat, but a spate of bad weather and technical problems with the final Falcon Heavy launch of the year kept the company short of 100 flights.
King of ‘upmass’
“Congrats to the entire Falcon team at SpaceX on a record breaking 96 launches in 2023!” wrote Jon Edwards, vice president of Falcon launch vehicles at SpaceX, on the social media platform X. “I remember when Elon Musk first threw out a goal of 100 launches as a thought experiment, intended to unlock our thinking as to how we might accelerate Falcon across all levels of production and launch.
“Only a few years later and here we are,” Edwards wrote. “I’m so incredibly proud to work with the best team on Earth, and so excited to see what we achieve next year.”
It’s important to step back and put these numbers in context. No other family of orbit-class rockets has ever flown more than 63 times in a year. SpaceX’s Falcon rockets have now exceeded this number by roughly 50 percent. SpaceX’s competitors in the United States, such as United Launch Alliance and Rocket Lab, managed far fewer flights in 2023. ULA had three missions, and Rocket Lab launched its small Electron booster 10 times.
Nearly two-thirds of SpaceX’s missions this year were dedicated to delivering satellites to orbit for SpaceX’s Starlink broadband network, a constellation that now numbers more than 5,000 spacecraft.
SpaceX also launched five missions with the Falcon Heavy rocket, created by aggregating three Falcon 9 rocket boosters together. Highlights from SpaceX’s 2023 Falcon launch schedule included three crew missions to the International Space Station, and the launch of NASA’s Psyche mission to explore a metallic asteroid.
In all, SpaceX’s Falcon rockets hauled approximately 1,200 metric tons, or more than 2.6 million pounds, of payload mass into orbit this year. This “upmass” is equivalent to nearly three International Space Stations. Most of this was made up of mass-produced Starlink satellites.
Enlarge/ Ship 28 is seen after being moved to SpaceX’s launch site in South Texas.
SpaceX
Just one month after the second flight of its massive Starship rocket, SpaceX is making progress toward a third attempt.
On Wednesday, at 1: 37 pm local time in South Texas, the company performed a static fire test of the next Starship—which bears the serial number Ship 28. The test of the rocket’s six engines appeared to be nominal as the Raptors ignited for a handful of seconds. The rocket and ground support equipment looked undamaged after the test.
Also this week SpaceX rolled the booster to be used for the next attempt—Booster 10—to the launch site at its Starbase facility in South Texas. The vehicle has since been lifted onto the orbital launch mount. Presumably this rocket, too, will undergo a static fire test in the coming days.
After these tests are complete the Starship upper stage is likely to be stacked on top of the booster to complete the launch vehicle. At this point it seems likely that the hardware for “Integrated Flight Test 3” would be substantially ready to launch.
With this third flight, SpaceX will seek to fly further into a profile that will see Starship ultimately make a controlled landing into the ocean north of Kauai, Hawaii. SpaceX may also perform an in-space propellant transfer test, but this has not been confirmed.
Starship’s second launch attempt, on November 18, was notably more successful than the first attempt in April 2023. The second flight test demonstrated substantial improvements in engine reliability and provided valuable data about a challenging “hot staging” maneuver to separate the Super Heavy booster from the Starship upper stage.
Another test flight soon?
Recently Kathy Lueders, SpaceX’s general manager for the Starbase launch site near Brownsville, said the company will target the first quarter of next year for this third test flight. “It would be great if we were in the first quarter, definitely,” she said. “Elon [Musk] obviously would probably say the end of December, but I don’t think we’ll get there.”
Since the second test flight occurred, neither the company nor SpaceX founder Elon Musk has provided a technical update on what ultimately went wrong with the Starship upper stage, which failed a few minutes into its flight, or why the booster was ultimately lost after it separated from the Starship vehicle.
Enlarge/ Booster 10, with a few holiday decorations, is rolled to the launch site in South Texas.
SpaceX
However, far fewer modifications have been made to the rocket hardware or the launch site ahead of this third attempt, suggesting that at least some of the problems may have been flight software-related.
SpaceX has yet to receive regulatory approval for a third launch of Starship. The Federal Aviation Administration characterized the second attempt in November as a “mishap,” while acknowledging that no injuries or public property damage were reported.
After the anomaly, the agency said, via the social media site X, that “the FAA will oversee the @SpaceX-led mishap investigation to ensure SpaceX complies with its FAA-approved mishap investigation plan and other regulatory requirements.” The FAA has provided no additional information in the month since then.
A SpaceX Falcon Heavy rocket is seen outside the company’s hangar at Kennedy Space Center, Florida.
SpaceX
SpaceX and the US Space Force thought they were ready to launch the military’s mysterious X-37B spaceplane this week, but ground teams in Florida need to roll the Falcon Heavy rocket back into its hangar for servicing.
This is expected to push back the launch until at least late December, perhaps longer. SpaceX and Space Force officials have not divulged details about the problems causing the delay.
SpaceX called off a launch attempt Monday night at NASA’s Kennedy Space Center in Florida to resolve a problem with a ground system. A senior Space Force official told Ars on Wednesday that additional issues will cause an additional delay in the launch.
“We’re working through a couple of technical glitches with our SpaceX team that just are going to take a little bit more time to work through,” said Col. James Horne, deputy director of the Space Force’s Assured Access to Space directorate. “We haven’t nailed down a specific launch date yet, but we’re going to have to roll back into the HIF (Horizontal Integration Facility) and work through some things on the rocket.”
Horne, a senior leader on the Space Force team overseeing military launches like this one, said the ground equipment problem that prevented liftoff Monday night could be fixed as soon as Wednesday. But it will take longer to resolve other issues he declined to specify. “We found some things that we need to run some analysis on, so that’s what’s driving the delay,” he said.
SpaceX was similarly vague in its explanation for the delay. In a post on the social media platform X, SpaceX said the company was standing down from the launch this week to “perform additional system checkouts.”
There’s a chance the Falcon Heavy might be back on the launch pad by the end of December or early next year. A SpaceX recovery vessel that was on station for the Falcon Heavy launch in the Atlantic Ocean is returning to shore, suggesting the launch won’t happen anytime soon.
“We’ve got to look at the schedule and balance that with all the other challenges,” Horne said. “But I hope we can get it off before the end of the year.”
Lunar launch date in jeopardy
When it’s ready to fly, the Falcon Heavy launch with the military’s X-37B spaceplane will likely get high priority on SpaceX’s launch schedule. The military’s launch ranges, like the one at Cape Canaveral, are primarily there to serve national security requirements, even though they get a lot more use from commercial space missions.
Depending on how long it’s delayed, this military launch could affect several SpaceX missions currently scheduled to fly in January. Most notably, a Falcon 9 rocket is slated to lift off from the same launch pad in January with the first commercial Moon lander from Intuitive Machines, a Houston-based company contracted to deliver scientific payloads to the lunar surface for NASA.
This robotic mission is one of the first two US-built spacecraft to attempt a Moon landing since the last Apollo landing in 1972. The Intuitive Machines mission, named IM-1, is scheduled to launch during a narrow window from January 12–16.
A few days earlier, as soon as January 8, another commercial lunar lander from Astrobotic is scheduled for liftoff from Cape Canaveral on the first test flight of United Launch Alliance’s new Vulcan rocket. The Astrobotic and Intuitive Machines missions can only launch a few days each month due to limitations imposed by orbital mechanics and lighting conditions at their landing sites. Astrobotic’s Peregrine lander was previously supposed to launch on December 24, but ULA pushed back the launch to perform more testing on the Vulcan rocket.
The landers from Astrobotic and Intuitive Machines are both at Cape Canaveral, waiting for their turn in the Florida spaceport’s busy launch manifest.
The IM-1 mission has to depart Earth from Launch Complex 39A, the same site previously used by the Saturn V rocket and space shuttle. SpaceX has outfitted the pad to top off the Intuitive Machines lander with cryogenic propellant just before launch, a capability unavailable at SpaceX’s other launch pad in Florida. Likewise, LC-39A is the only launch pad capable of supporting Falcon Heavy missions.
It usually takes a couple of weeks to reconfigure LC-39A between Falcon Heavy and Falcon 9 launches. The Falcon Heavy is significantly more powerful, with three Falcon 9 first-stage boosters connected together to haul more massive payloads into orbit.
A private astronaut mission managed by Axiom Space is also in the mix, with a launch date set for January 9. This mission, known as Ax-3, will carry four commercial astronauts aboard a Falcon 9 rocket and Dragon spacecraft on a roughly two-week flight to the International Space Station. Sarah Walker, director of Dragon mission management at SpaceX, said the company hasn’t decided which pad Ax-3 will launch from.
All of SpaceX’s crew missions to date have lifted off from LC-39A, but the company recently constructed a crew access tower and arm to enable astronaut flights to depart from nearby Space Launch Complex 40. This gives SpaceX some flexibility to alleviate launch bottlenecks at LC-39A, which is required for some of the company’s most important missions.
LC-39A will remain the primary launch pad for SpaceX’s crew missions, Walker said Wednesday, but she added: “Having the second pad available enables us to be ultra-responsive to customer needs and growing demand by moving a Dragon over to SLC-40 when the need arises.”
It’s a good problem to have so many interesting payloads vying for a launch slot with SpaceX, but the tyranny of physics and infrastructure constraints could mean one of these missions might have to wait a little longer for a ride to space.
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.
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.
Enlarge/ The Hubble Space Telescope viewed from Space Shuttle Atlantis during a servicing mission in 2009.
NASA
The Hubble Space Telescope resumed science observations on Friday after ground teams spent most of the last three weeks assessing the performance of a finicky gyroscope, NASA said.
The troublesome gyroscope is a critical part of the observatory’s pointing system. Hubble’s gyros measure how fast the spacecraft is turning, helping the telescope aim its aperture toward distant cosmic wonders.
Hubble still provides valuable scientific data for astronomers nearly 34 years since its launch aboard NASA’s Space Shuttle Discovery in 1990. Five more shuttle servicing missions repaired Hubble, upgraded its science instruments, and replaced hardware degraded from long-term use in space. Among other tasks, astronauts on the last of the shuttle repair flights in 2009 installed six new gyroscopes on Hubble.
Moving parts sometimes break
The gyros have long been one of the parts of Hubble that require the most upkeep. A wheel inside each gyro spins at a constant rate of 19,200 revolutions per minute, and the wheel is, in turn, sealed inside a cylinder suspended in a thick fluid, according to NASA. Electronics within each gyro detect very small movements of the axis of the wheel, which supply Hubble’s central computer with information about the spacecraft’s turn rate. Hair-thin wires route signals from the gyroscopes, and these wires can degrade over time.
Three of the six gyros installed on Hubble in 2009 have failed, and three others remain operational. The three still-functioning gyros are based on a newer design for longer life, but one of these units has shown signs of wear in the last few months. This gyroscope, designated Gyro 3, has always exhibited “consistent noisy behavior,” said Pat Crouse, Hubble project manager at NASA’s Goddard Space Flight Center.
Hubble typically needs three gyros to operate normally, so ground controllers shut down Gyro 3 for roughly seven years until Hubble needed it in 2018, when another gyroscope failed, leaving only three of the devices still working.
“Back in August, we saw issues,” Crouse told Ars this week. “It would sort of sporadically output some rate information that was not consistent with the observed spacecraft body rates, but it was short-lived, and we were characterizing what that performance was like and how much we could tolerate.”
The gyro’s performance worsened in November when it fed Hubble’s control system erroneous data. The gyroscope sensed that the spacecraft was changing its orientation when it really wasn’t moving. “That, then, contributed to an error in attitude that was kind of causing a little bit of drift,” Crouse said.
Automated software on Hubble detected the errors and put the spacecraft into “safe mode” two times last month. Hubble quickly resumed science observations each time but then went into safe mode again on November 23. Hubble managers took some extra time to gather data on the gyro’s health. Engineers commanded Hubble to move back and forth, and the suspect gyro consistently seemed to work well.
