FAA

It seems the FAA office overseeing SpaceX’s Starship probe still has some bite

Commercial space, elon musk, FAA, launch, Science, Space, spacex, starship, starship flight 7 / Mike M. / February 2, 2025

The political winds have shifted in Washington, but the FAA hasn’t yet changed its tune on Starship.

Liftoff of SpaceX’s seventh full-scale test flight of the Super Heavy/Starship launch vehicle on January 16. Credit: SpaceX

The seventh test flight of SpaceX’s gigantic Starship rocket came to a disappointing end a little more than two weeks ago. The in-flight failure of the rocket’s upper stage, or ship, about eight minutes after launch on January 16 rained debris over the Turks and Caicos Islands and the Atlantic Ocean.

Amateur videos recorded from land, sea, and air showed fiery debris trails streaming overhead at twilight, appearing like a fireworks display gone wrong. Within hours, posts on social media showed small pieces of debris recovered by residents and tourists in the Turks and Caicos. Most of these items were modest in size, and many appeared to be chunks of tiles from Starship’s heat shield.

Unsurprisingly, the Federal Aviation Administration grounded Starship and ordered an investigation into the accident on the day after the launch. This decision came three days before the inauguration of President Donald Trump. Elon Musk’s close relationship with Trump, coupled with the new administration’s appetite for cutting regulations and reducing the size of government, led some industry watchers to question whether Musk’s influence might change the FAA’s stance on SpaceX.

So far, the FAA hasn’t budged on its requirement for an investigation, an agency spokesperson told Ars on Friday. After a preliminary assessment of flight data, SpaceX officials said a fire appeared to develop in the aft section of the ship before it broke apart and fell to Earth.

“The FAA has directed SpaceX to lead an investigation of the Starship Super Heavy Flight 7 mishap with FAA oversight,” the spokesperson said. “Based on the investigation findings for root cause and corrective actions, the FAA may require a company to modify its license.”

This is much the same language the FAA used two weeks ago, when it first ordered the investigation.

Damage report

The FAA’s Office of Commercial Space Transportation is charged with ensuring commercial space launches and reentries don’t endanger the public, and requires launch operators obtain liability insurance or demonstrate financial ability to cover any third-party property damages.

For each Starship launch, the FAA requires SpaceX maintain liability insurance policies worth at least $500 million for such claims. It’s rare for debris from US rockets to fall over land during a launch. This would typically only happen if a launch failed at certain parts of the flight. And there’s no public record of any claims of third-party property damage in the era of commercial spaceflight. Under federal law, the US government would pay for damages to a much higher amount if any claims exceeded a launch company’s insurance policies.

Here’s a piece of Starship 33 @SpaceX @elonmusk found in Turks and Caicos! 🚀🏝️ pic.twitter.com/HPZDCqA9MV

— @maximzavet (@MaximZavet) January 17, 2025

The good news is there were no injuries or reports of significant damage from the wreckage that fell over the Turks and Caicos. “The FAA confirmed one report of minor damage to a vehicle located in South Caicos,” an FAA spokesperson told Ars on Friday. “To date, there are no other reports of damage.”

It’s not clear if the vehicle owner in South Caicos will file a claim against SpaceX for the damage. It would the first time someone makes such a claim related to an accident with a commercial rocket overseen by the FAA. Last year, a Florida homeowner submitted a claim to NASA for damage to his house from a piece of debris that fell from the International Space Station.

Nevertheless, the Turks and Caicos government said local officials met with representatives from SpaceX and the UK Air Accident Investigations Branch on January 25 to develop a recovery plan for debris that fell on the islands, which are a British Overseas Territory.

A prickly relationship

Musk often bristled at the FAA last year, especially after regulators proposed fines of more than $600,000 alleging that SpaceX violated terms of its launch licenses during two Falcon 9 missions. The alleged violations involved the relocation of a propellant farm at one of SpaceX’s launch pads in Florida, and the use of a new launch control center without FAA approval.

In a post on X, Musk said the FAA was conducting “lawfare” against his company. “SpaceX will be filing suit against the FAA for regulatory overreach,” Musk wrote.

There was no such lawsuit, and the issue may now be moot. Sean Duffy, Trump’s new secretary of transportation, vowed to review the FAA fines during his confirmation hearing in the Senate. It is rare for the FAA to fine launch companies, and the fines last year made up the largest civil penalty ever imposed by the FAA’s commercial spaceflight division.

SpaceX also criticized delays in licensing Starship test flights last year. The FAA cited environmental issues and concerns about the extent of the sonic boom from Starship’s 23-story-tall Super Heavy booster returning to its launch pad in South Texas. SpaceX successfully caught the returning first stage booster at the launch pad for the first time in October, and repeated the feat after the January 16 test flight.

What separates the FAA’s ongoing oversight of Starship’s recent launch failure from these previous regulatory squabbles is that debris fell over populated areas. This would appear to be directly in line with the FAA’s responsibility for public safety.

During last month’s test flight, Starship did not deviate from its planned ground track, which took the rocket over the Gulf of Mexico, the waters between Florida and Cuba, and then the Atlantic Ocean. But the debris field extended beyond the standard airspace closure for the launch. After the accident, FAA air traffic controllers cleared additional airspace over the debris zone for more than an hour, rerouting, diverting, and delaying dozens of commercial aircraft.

These actions followed pre-established protocols. However, it highlighted the small but non-zero risk of rocket debris falling to Earth after a launch failure. “The potential for a bad day downrange just got real,” Lori Garver, a former NASA deputy administrator, posted on X.

Public safety is not sole mandate of the FAA’s commercial space office. It is also chartered to “encourage, facilitate, and promote commercial space launches and reentries by the private sector,” according to an FAA website. There’s a balance to strike.

Lawmakers last year urged the FAA to speed up its launch approvals, primarily because Starship is central to strategic national objectives. NASA has contracts with SpaceX to develop a variant of Starship to land astronauts on the Moon, and Starship’s unmatched ability to deliver more than 100 tons of cargo to low-Earth orbit is attractive to the Pentagon.

While Musk criticized the FAA in 2024, SpaceX officials in 2023 took a different tone, calling for Congress to increase the budget for the FAA’s Office of Commercial Spaceflight and for the regulator to double the space division’s workforce. This change, SpaceX officials argued, would allow the FAA to more rapidly assess and approve a fast-growing number of commercial launch and reentry applications.

In September, SpaceX released a statement accusing the former administrator of the FAA, Michael Whitaker, of making inaccurate statements about SpaceX to a congressional subcommittee. In a different post on X, Musk directly called for Whitaker’s resignation.

He needs to resign https://t.co/pG8htfTYHb

— Elon Musk (@elonmusk) September 25, 2024

That’s exactly what happened. Whitaker, who took over the FAA’s top job in 2023 under the Biden administration, announced in December he would resign on Inauguration Day. Since the agency’s establishment in 1958, three FAA administrators have similarly resigned when a new administration takes power, but the office has been largely immune from presidential politics in recent decades. Since 1993, FAA administrators have stayed in their post during all presidential transitions.

There’s no evidence Whitaker’s resignation had any role in the mid-air collision of an American Eagle passenger jet and a US Army helicopter Wednesday night near Ronald Reagan Washington National Airport. But his departure from the FAA less than two years into a five-year term on January 20 left the agency without a leader. Trump named Chris Rocheleau as the FAA’s acting administrator Thursday.

Next flight, next month?

SpaceX has not released an official schedule for the next Starship test flight or outlined its precise objectives. However, it will likely repeat many of the goals planned for the previous flight, which ended before SpaceX could accomplish some of its test goals. These missed objectives included the release of satellite mockups in space for the first demonstration of Starship’s payload deployment mechanism, and a reentry over the Indian Ocean to test new, more durable heat shield materials.

The January 16 test flight was the first launch up an upgraded, slightly taller Starship, known as Version 2 or Block 2. The next flight will use the same upgraded version.

A SpaceX filing with the Federal Communications Commission suggests the next Starship flight could launch as soon as February 24. Sources told Ars that SpaceX teams believe a launch before the end of February is realistic.

But SpaceX has more to do before Flight 8. These tasks include completing the FAA-mandated investigation and the installation of all 39 Raptor engines on the rocket. Then, SpaceX will likely test-fire the booster and ship before stacking the two elements together to complete assembly of the 404-foot-tall (123.1-meter) rocket.

SpaceX is also awaiting a new FAA launch license, pending its completion of the investigation into what happened on Flight 7.

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

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Fire destroys Starship on its seventh test flight, raining debris from space

Commercial space, FAA, Features, launch, NASA, Science, Space, spacex, Starbase, starship / DJ Henderson / January 18, 2025

This launch debuted a more advanced, slightly taller version of Starship, known as Version 2 or Block 2, with larger propellant tanks, a new avionics system, and redesigned feed lines flowing methane and liquid oxygen propellants to the ship’s six Raptor engines. SpaceX officials did not say whether any of these changes might have caused the problem on Thursday’s launch.

SpaceX officials have repeatedly and carefully set expectations for each Starship test flight. They routinely refer to the rocket as experimental, and the primary focus of the rocket’s early demo missions is to gather data on the performance of the vehicle. What works, and what doesn’t work?

Still, the outcome of Thursday’s test flight is a clear disappointment for SpaceX. This was the seventh test flight of SpaceX’s enormous rocket and the first time Starship failed to complete its launch sequence since the second flight in November 2023. Until now, SpaceX has made steady progress, and each Starship flight has achieved more milestones than the one before.

On the first flight in April 2023, the rocket lost control a little more than two minutes after liftoff, and the ground-shaking power of the booster’s 33 engines shattered the concrete foundation beneath the launch pad. Seven months later, on Flight 2, the rocket made it eight minutes before failing. On that mission, Starship failed at roughly the same point of its ascent, just before the cutoff of the vehicle’s six methane-fueled Raptor engines.

Back then, a handful of photos and images from the Florida Keys and Puerto Rico showed debris in the sky after Starship activated its self-destruct mechanism due to an onboard fire caused by a dump of liquid oxygen propellant. But that flight occurred in the morning, with bright sunlight along the ship’s flight path.

This time, the ship disintegrated and reentered the atmosphere at dusk, with impeccable lighting conditions accentuating the debris cloud’s appearance. These twilight conditions likely contributed to the plethora of videos posted to social media on Thursday.

Starship and Super Heavy head downrange from SpaceX’s launch site near Brownsville, Texas. Credit: SpaceX

The third Starship test flight last March saw the spacecraft reach its planned trajectory and fly halfway around the world before succumbing to the scorching heat of atmospheric reentry. In June, the fourth test flight ended with controlled splashdowns of the rocket’s Super Heavy booster in the Gulf of Mexico and of Starship in the Indian Ocean.

In October, SpaceX caught the Super Heavy booster with mechanical arms at the launch pad for the first time, proving out the company’s audacious approach to recovering and reusing the rocket. On this fifth test flight, SpaceX modified the ship’s heat shield to better handle the hot temperatures of reentry, and the vehicle again made it to an on-target splashdown in the Indian Ocean.

Most recently, Flight 6 on November 19 demonstrated the ship’s ability to reignite its Raptor engines in space for the first time and again concluded with a bullseye splashdown. But SpaceX aborted an attempt to again catch the booster back at Starbase due to a problem with sensors on the launch pad’s tower.

With Flight 7, SpaceX hoped to test more changes to the heat shield protecting Starship from reentry temperatures up to 2,600° Fahrenheit (1,430° Celsius). Musk has identified the heat shield as one of the most difficult challenges still facing the program. In order for SpaceX to reach its ambition for the ship to become rapidly reusable, with minimal or no refurbishment between flights, the heat shield must be resilient and durable.

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SpaceX just got exactly what it wanted from the FAA for Texas Starship launches

FAA, Science, Space, spacex / Beth Washington / November 20, 2024

And there will be significant impacts. For example, the number of large trucks that deliver water, liquid oxygen, methane, and other commodities will increase substantially. According to the FAA document, the vehicle presence will grow from an estimated 6,000 trucks a year to 23,771 trucks annually. This number could be reduced by running a water line along State Highway 4 to supply the launch site’s water deluge system.

SpaceX has made progress in some areas, the document notes. For example, in terms of road closures for testing and launch activities, SpaceX has reduced the duration of closures along State Highway 4 to Boca Chica Beach by 85 percent between the first and third flight of Starship. This has partly been accomplished by moving launch preparation activities to the “Massey’s Test Site,” located about four miles from the launch site. SpaceX is now expected to need less than 20 hours of access restrictions per launch campaign, including landings.

SpaceX clearly got what it wanted

If finalized, this environmental assessment will give SpaceX the regulatory greenlight to match its aspirations for launches in at least 2025, if not beyond. During recent public meetings, SpaceX’s general manager of Starbase, Kathy Lueders, has said the company aims to launch Starship 25 times next year from Texas. The new regulations would permit this.

Additionally, SpaceX founder Elon Musk has said the company intends to move to a larger and more powerful version of the Starship and Super Heavy rocket about a year from now. This version, dubbed Starship 3, would double the thrust of the upper stage and increase the thrust of the booster stage from about 74 meganewtons to about 100 meganewtons. If that number seems a little abstract, another way to think about it is that Starship would have a thrust at liftoff three times as powerful as NASA’s Saturn V rocket that launched humans to the Moon decades ago. The draft environmental assessment permits this as well.

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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 / Shannon Garcia / July 29, 2024

A superfluity of Starships —

“SpaceX has dramatically reduced the duration of operations.”

Eric Berger – Jul 29, 2024 6: 20 pm UTC

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.

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.

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