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SpaceX’s workhorse launch pad now has the accoutrements for astronauts

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A Falcon 9 rocket lifts off Thursday from Cape Canaveral, Florida.

Enlarge / A Falcon 9 rocket lifts off Thursday from Cape Canaveral, Florida.

Upgrades at SpaceX’s most-used launch pad in Florida got a trial run Thursday with the liftoff of a Falcon 9 rocket with a Dragon cargo ship heading for the International Space Station.

SpaceX’s Cargo Dragon spacecraft launched at 4: 55 pm EDT (20: 55 UTC) Thursday from Space Launch Complex 40 (SLC-40) at Cape Canaveral Space Force Station in Florida. This mission, known as CRS-30, is SpaceX’s 30th resupply mission to the space station since 2012.

The automated Dragon supply ship took off on top of a Falcon 9 rocket, heading for a monthlong stay at the International Space Station, where it will deliver more than 6,000 pounds of hardware, fresh food, and experiments for the lab’s seven-person crew.

In the last few months, SpaceX has outfitted the launch pad with the equipment necessary to support launches of human spaceflight missions on the Crew Dragon spacecraft. The Cargo Dragon capsule is the same size and shape as SpaceX’s Crew Dragon, but it’s filled with cargo racks and storage platforms rather than seats and cockpit displays.

This week, SpaceX technicians used the newly installed launch tower and crew access arm at SLC-40 to load time-sensitive experiments and supplies into the Cargo Dragon capsule atop the Falcon 9 rocket.

“CRS-30 will be our first Dragon to launch from Pad 40 since we put that brand-new crew tower in place,” said Sarah Walker, SpaceX’s director of Dragon mission management, in a prelaunch press conference.

Building new capability

Starting last year, construction crews at Cape Canaveral erected segments of a more than 200-foot-tall metal lattice tower at SLC-40, right next to the starting blocks for SpaceX’s Falcon 9 rocket. Before then, SLC-40 was based on a “clean pad” architecture, without any structures to service or access Falcon 9 rockets while they were vertical on the pad.

In November, contractors raised the crew access arm to an attach point near the top of the tower. This walkway will allow astronauts to crawl into the Crew Dragon spacecraft during a launch countdown. It also provides access to the hatch on the Cargo Dragon spacecraft for final cargo loading.

Earlier this year, SpaceX tested an escape chute at SLC-40 that would be used in an emergency to help astronauts and ground crews quickly get away from the pad. The chute is similar in function to slide-wire baskets in use for decades at LC-39A, but instead of riding a basket from the top of the tower, personnel escaping a pad emergency would slide down a chute to carry them several hundred feet from the rocket.

SpaceX employees tested the pad escape chute last month at SLC-40. Gwynne Shotwell, SpaceX’s president and chief operating officer, took the ride down the chute. “Astronaut and personnel safety is SpaceX’s highest priority, which is why I had to personally test the new slide,” she posted on X, alongside a wink emoji.

Teams test the new emergency chutes from the pad 40 crew tower in Florida pic.twitter.com/rWVj7zaHp0

— SpaceX (@SpaceX) March 19, 2024

“The team took commercially available off the shelf technology and applied it to the crew tower,” Kiko Dontchev, SpaceX’s vice president of launch, wrote on X. “You are trained on it the same way you are trained on using an emergency exit door on airplane. Only takes a couple of quick physical actions to deploy the slide and anyone can effectively do it.”

As more people travel to space, particularly on larger vehicles like SpaceX’s Starship, simplifying safety systems will be important.

“This system will help us scale to bigger towers and spaceships (think 100 people on Starship),” Dontchev wrote.

SpaceX and its contractors completed all of this work as Falcon 9s fired off SLC-40 every few days with Starlink satellites and other missions.

For the last four years, all of SpaceX’s crew and cargo launches to the space station have departed from Launch Complex 39A (LC-39A) at NASA’s Kennedy Space Center, a few miles up the coast from SLC-40. In 2018 and 2019, SpaceX outfitted LC-39A for Cargo Dragon and Crew Dragon missions ahead of the company’s first human spaceflight mission in 2020.

Walker said the new infrastructure added at SLC-40 is “nearly functionally identical” to the equipment for crew missions at LC-39A. The primary differences are the means of pad escape—the chute instead of slide-wire baskets—and a more robust elevator in the tower at SLC-40.

Previously, SpaceX used both SLC-40 and LC-39A for launches of its now-retired first-generation Dragon cargo capsules, which had their final supplies loaded before SpaceX raised the rocket vertical for launch. Like regular satellite launches on Falcon 9s, both pads could support the first-generation Dragon cargo missions.

“Thanks to this new state-of-the-art crew tower required for our human spaceflight missions, that late-load cargo operation got a massive upgrade, too,” Walker said. “It is much easier to load a huge complement of time-critical NASA science into our Dragon spacecraft in the flight orientation.”

SpaceX has drastically ramped up its launch cadence since building LC-39A for Dragon missions. The company plans nearly 150 Falcon 9 or Falcon Heavy launches this year. When you’re flying rockets every two or three days, it’s inevitable two missions will end up vying for the same launch slots. Most recently, that happened in February, when a NASA crew mission was ready to launch from LC-39A around the same time as a narrow launch window for Intuitive Machines’ first commercial lunar lander. Both had to go off of LC-39A.

“Historically, Pad 40 has kind of become our high rate pad,” Walker said. “We’ve gotten the time between launches down to just a couple of days.”

LC-39A has seen less use, primarily for Dragon crew and cargo flights, Falcon Heavy missions, and other “uniquely complex” missions like the Intuitive Machines lander, Walker said.

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The world’s most-traveled crew transport spacecraft flies again

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A SpaceX Falcon 9 rocket lifts off with the Crew-8 mission, sending three NASA astronauts and one Russian cosmonaut on a six-month expedition on the International Space Station.

Enlarge / A SpaceX Falcon 9 rocket lifts off with the Crew-8 mission, sending three NASA astronauts and one Russian cosmonaut on a six-month expedition on the International Space Station.

SpaceX’s oldest Crew Dragon spacecraft launched Sunday night on its fifth mission to the International Space Station, and engineers are crunching data to see if the fleet of Dragons can safely fly as many as 15 times.

It has been five years since SpaceX launched the first Crew Dragon spacecraft on an unpiloted test flight to the space station and nearly four years since SpaceX’s first astronaut mission took off in May 2020. Since then, SpaceX has put its clan of Dragons to use ferrying astronauts and cargo to and from low-Earth orbit.

Now, it’s already time to talk about extending the life of the Dragon spaceships. SpaceX and NASA, which shared the cost of developing the Crew Dragon, initially certified each capsule for five flights. Crew Dragon Endeavour, the first in the Dragon fleet to carry astronauts, is now flying for the fifth time.

This ship has spent 466 days in orbit, longer than any spacecraft designed to transport people to and from Earth. It will add roughly 180 days to its flight log with this mission.

Crew Dragon Endeavour lifted off from Florida aboard a Falcon 9 rocket at 10: 53 pm EST Sunday (03: 53 UTC Monday), following a three-day delay due to poor weather conditions across the Atlantic Ocean, where the capsule would ditch into the sea in the event of a rocket failure during the climb into orbit.

Commander Matthew Dominick, pilot Michael Barratt, mission specialist Jeanette Epps, and Russian cosmonaut Alexander Grebenkin put on their SpaceX pressure suits and strapped into their seats inside Crew Dragon Endeavour Sunday evening at NASA’s Kennedy Space Center. SpaceX loaded liquid propellants into the rocket, while ground teams spent the final hour of the countdown evaluating a small crack discovered on Dragon’s side hatch seal. Managers ultimately cleared the spacecraft for launch after considering whether the crack could pose a safety threat during reentry at the end of the mission.

“We are confident that we understand the issue and can still fly the whole mission safely,” a member of SpaceX’s mission control team told the crew inside Dragon.

This mission, known as Crew-8, launched on a brand-new Falcon 9 booster, which returned to landing a few minutes after liftoff at Cape Canaveral Space Force Station. The Falcon 9’s upper stage released the Dragon spacecraft into orbit about 12 minutes after liftoff. The four-person crew will dock at the space station around 3 am EST (0800 UTC) Tuesday.

Crew-8 will replace the four-person Crew-7 team that has been at the space station since last August. Crew-7 will return to Earth in about one week on SpaceX’s Crew Dragon Endurance spacecraft, which is flying in space for the third time.

The Crew-8 mission came home for a reentry and splashdown off the coast of Florida in late August of this year, wrapping up Crew Dragon Endeavour’s fifth trip to space. This is the current life limit for a Crew Dragon spacecraft, but don’t count out Endeavour just yet.

Fleet management

“Right now, we’re certified for five flights on Dragon, and we’re looking at extending that life out,” said Steve Stich, NASA’s commercial crew program manager. “I think the goal would be for SpaceX to say 15 flights of Dragon. We may not get there in every single system.”

One by one, engineers at SpaceX and NASA are looking at Dragon’s structural skeleton, composite shells, rocket engines, valves, and other components to see how much life is left in them. Some parts of the spacecraft slowly fatigue from the stresses of each launch, reentry, and splashdown, along with the extreme temperature swings the capsule sees thousands of times in orbit. Each Draco thruster on the spacecraft is certified for a certain number of firings.

Some components are already approved for 15 flights, Stich said in a recent press conference. “Some, we’re still in the middle of working on,” he said. “Some of those components have to go through some re-qualification to make sure that they can make it out to 15 flights.”

Re-qualifying a component on a spacecraft typically involves putting hardware through extensive testing on the ground. Because SpaceX reuses hardware, engineers can remove a part from a flown Dragon spacecraft and put it through qualification testing. NASA will get the final say in certifying the Dragon spacecraft for additional flights because the agency is SpaceX’s primary customer for crew missions.

The Dragon fleet is flying more often than SpaceX or NASA originally anticipated. The main reason for this is that Boeing, NASA’s other commercial crew contractor, is running about four years behind SpaceX in getting to its first astronaut launch on the Starliner spacecraft.

When NASA selected SpaceX and Boeing for multibillion-dollar commercial crew contracts in 2014, the agency envisioned alternating between Crew Dragon and Starliner flights every six months to rotate four-person crews at the International Space Station. With Boeing’s delays, SpaceX has picked up the slack.

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SpaceX launches military satellites tuned to track hypersonic missiles

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Trackers —

These satellites will participate in joint missile tracking exercises later this year.

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SpaceX launched a Falcon 9 rocket Wednesday with six missile-tracking satellites for the US military.

Enlarge / SpaceX launched a Falcon 9 rocket Wednesday with six missile-tracking satellites for the US military.

Two prototype satellites for the Missile Defense Agency and four missile tracking satellites for the US Space Force rode a SpaceX Falcon 9 rocket into orbit Wednesday from Florida’s Space Coast.

These satellites are part of a new generation of spacecraft designed to track hypersonic missiles launched by China or Russia and perhaps emerging missile threats from Iran or North Korea, which are developing their own hypersonic weapons.

Hypersonic missiles are smaller and more maneuverable than conventional ballistic missiles, which the US military’s legacy missile defense satellites can detect when they launch. Infrared sensors on the military’s older-generation missile tracking satellites are tuned to pick out bright thermal signatures from missile exhaust.

The new threat paradigm

Hypersonic missiles represent a new challenge for the Space Force and the Missile Defense Agency (MDA). For one thing, ballistic missiles follow a predictable parabolic trajectory that takes them into space. Hypersonic missiles are smaller and comparatively dim, and they spend more time flying in Earth’s atmosphere. Their maneuverability makes them difficult to track.

A nearly 5-year-old military organization called the Space Development Agency (SDA) has launched 27 prototype satellites over the last year to prove the Pentagon’s concept for a constellation of hundreds of small, relatively low-cost spacecraft in low-Earth orbit. This new fleet of satellites, which the SDA calls the Proliferated Warfighter Space Architecture (PWSA), will eventually number hundreds of spacecraft to track missiles and relay data about their flight paths down to the ground. The tracking data will provide an early warning to those targeted by hypersonic missiles and help generate a firing solution for interceptors to shoot them down.

The SDA constellation combines conventional tactical radio links, laser inter-satellite communications, and wide-view infrared sensors. The agency, now part of the Space Force, plans to launch successive generations, or tranches, of small satellites, each introducing new technology. The SDA’s approach relies on commercially available spacecraft and sensor technology and will be more resilient to attack from an adversary than the military’s conventional space assets. Those legacy military satellites often cost hundreds of millions or billions of dollars apiece, with architectures that rely on small numbers of large satellites that might appear like a sitting duck to an adversary determined to inflict damage.

Four of the small SDA satellites and two larger spacecraft for the Missile Defense Agency were aboard a SpaceX Falcon 9 rocket when it lifted off from Cape Canaveral Space Force Station at 5: 30 pm EST (2230 UTC) Wednesday.

The rocket headed northeast from Cape Canaveral to place the six payloads into low-Earth orbit. Officials from the Space Force declared the launch a success later Wednesday evening.

The SDA’s four tracking satellites, built by L3Harris, are the last spacecraft the agency will launch in its prototype constellation, called Tranche 0. Beginning later this year, the SDA plans to kick off a rapid-fire launch campaign with SpaceX and United Launch Alliance to quickly build out its operational Tranche 1 constellation, with launches set to occur at one-month intervals to deploy approximately 150 satellites. Then, there will be a Tranche 2 constellation with more advanced sensor technologies.

The primary payloads aboard Wednesday’s launch were for the MDA. These two Hypersonic and Ballistic Tracking Space Sensor (HBTSS) satellites, one supplied by L3Harris and the other by Northrop Grumman, will demonstrate medium field-of-view sensors. Those sensors can’t cover as much territory as the SDA satellites but will provide more sensitive and detailed missile tracking data.

This illustration shows how the HBTSS satellites can track hypersonic missiles as they glide and maneuver through the atmosphere, evading detection by conventional missile tracking spacecraft, such as the Space Force's DSP and SBIRS satellites.

This illustration shows how the HBTSS satellites can track hypersonic missiles as they glide and maneuver through the atmosphere, evading detection by conventional missile tracking spacecraft, such as the Space Force’s DSP and SBIRS satellites.

“Our advanced satellites on orbit will bring the integrated and resilient missile warning and defense capabilities the US requires against adversaries developing more advanced maneuverable missiles,” said Christopher Kubasik, chairman and CEO of L3Harris. “L3Harris delivered this advanced missile tracking capability on behalf of MDA and SDA on orbit in just over three years after work was authorized to proceed. We are proud to be a critical part of the new space sensing architecture.”

The HBTSS satellites, valued at more than $300 million, and the SDA’s tracking prototypes will participate in joint military exercises in the coming months, where the wide-view SDA satellites will provide “cueing data” to the MDA’s HBTSS spacecraft. The narrower field of view of the HBTSS satellites can provide more specific, target-quality data to a ground-based interceptor, according to a report last year published by the Congressional Research Service. Future tranches, or generations, of SDA satellites will incorporate the medium field-of-view sensing capability flying on the MDA’s HBTSS satellites.

With SDA taking over the responsibility for making this technology operational, that will leave the MDA, which has historically flown its own missile tracking satellites, focused on next-generation sensor development, an MDA spokesperson told Ars.

Military officials decided only last year to place the four SDA satellites on the same launch as the MDA’s HBTSS mission. With all six satellites flying in the same orbital plane, there will be opportunities to see the same targets with both types of spacecraft and sensors. These targets may include scheduled US military missile tests or foreign launches.

“The intent to be able to work with cooperative and noncooperative targets to be able to do our demonstrations,” a senior SDA official said during a background briefing.

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Axiom, SpaceX launch third all-private crew mission to space station

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Flying private —

A US-Spanish dual citizen commands a crew of Italian, Swedish, and Turkish astronauts.

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A Falcon 9 rocket lifts off from NASA's Kennedy Space Center to begin the Ax-3 commercial crew mission.

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.

Michael López-Alegría, Alper Gezeravcı, Marcus Wandt, and Walter Villadei pose inside SpaceX's crew access arm at Launch Complex 39A in Florida.

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.

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A commander’s lament on the loss of a historic SpaceX rocket

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Museum piece —

This rocket restored NASA crew launches to US soil, then launched 18 more times.

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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.

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.”

Doug Hurley, right, commanded the Crew Dragon spacecraft on the Demo-2 mission in 2020.

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.

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SpaceX launches two rockets—three hours apart—to close out a record year

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SpaceX's Falcon Heavy rocket lifted off Thursday night from NASA's Kennedy Space Center in Florida.

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.

SpaceX launches two rockets—three hours apart—to close out a record year Read More »