Kennedy Space Center

With another record broken, the world’s busiest spaceport keeps getting busier

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It’s not just the number of rocket launches, but how much stuff they’re carrying into orbit.

With 29 Starlink satellites onboard, a Falcon 9 rocket streaks through the night sky over Cape Canaveral Space Force Station, Florida, on Monday night. Credit: Stephen Clark/Ars Technica

CAPE CANAVERAL, Florida—Another Falcon 9 rocket fired off its launch pad here on Monday night, taking with it another 29 Starlink Internet satellites to orbit.

This was the 94th orbital launch from Florida’s Space Coast so far in 2025, breaking the previous record for the most satellite launches in a calendar year from the world’s busiest spaceport. Monday night’s launch came two days after a Chinese Long March 11 rocket lifted off from an oceangoing platform on the opposite side of the world, marking humanity’s 255th mission to reach orbit this year, a new annual record for global launch activity.

As of Wednesday, a handful of additional missions have pushed the global figure this year to 259, putting the world on pace for around 300 orbital launches by the end of 2025. This will more than double the global tally of 135 orbital launches in 2021.

Routine vs. complacency

Waiting in the darkness a few miles away from the launch pad, I glanced around at my surroundings before watching SpaceX’s Falcon 9 thunder into the sky. There were no throngs of space enthusiasts anxiously waiting for the rocket to light up the night. No line of photographers snapping photos. Just this reporter and two chipper retirees enjoying what a decade ago would have attracted far more attention.

Go to your local airport and you’ll probably find more people posted up at a plane-spotting park at the end of the runway. Still, a rocket launch is something special. On the same night that I watched the 94th launch of the year depart from Cape Canaveral, Orlando International Airport saw the same number of airplane departures in just three hours.

The crowds still turn out for more meaningful launches, such as a test flight of SpaceX’s Starship megarocket in Texas or Blue Origin’s attempt to launch its second New Glenn heavy-lifter here Sunday. But those are not the norm. Generations of aerospace engineers were taught that spaceflight is not routine for fear of falling into complacency, leading to failure, and in some cases, death.

Compared to air travel, the mantra remains valid. Rockets are unforgiving, with engines operating under extreme pressures, at high thrust, and unable to suck in oxygen from the atmosphere as a reactant for combustion. There are fewer redundancies in a rocket than in an airplane.

The Falcon 9’s established failure rate is less than 1 percent, well short of any safety standard for commercial air travel but good enough to be the most successful orbital-class in history. Given the Falcon 9’s track record, SpaceX seems to have found a way to overcome the temptation for complacency.

A Chinese Long March 11 rocket carrying three Shiyan 32 test satellites lifts off from waters off the coast of Haiyang in eastern China’s Shandong province on Saturday. Credit: Guo Jinqi/Xinhua via Getty Images

Following the trend

The upward trend in rocket launches hasn’t always been the case. Launch numbers were steady for most of the 2010s, following a downward trend in the 2000s, with as few as 52 orbital launches in 2005, the lowest number since the nascent era of spaceflight in 1961. There were just seven launches from here in Florida that year.

The numbers have picked up dramatically in the last five years as SpaceX has mastered reusable rocketry.

It’s important to look at not just the number of launches but also how much stuff rockets are actually putting into orbit. More than half of this year’s launches were performed using SpaceX’s Falcon 9 rocket, and the majority of those deployed Starlink satellites for SpaceX’s global Internet network. Each spacecraft is relatively small in size and weight, but SpaceX stacks up to 29 of them on a single Falcon 9 to max out the rocket’s carrying capacity.

All this mass adds up to make SpaceX’s dominance of the launch industry appear even more absolute. According to analyses by BryceTech, an engineering and space industry consulting firm, SpaceX has launched 86 percent of all the world’s payload mass over the 18 months from the beginning of 2024 through June 30 of this year.

That’s roughly 2.98 million kilograms of the approximately 3.46 million kilograms (3,281 of 3,819 tons) of satellite hardware and cargo that all the world’s rockets placed into orbit during that timeframe.

The charts below were created by Ars Technica using publicly available launch numbers and payload mass estimates from BryceTech. The first illustrates the rising launch cadence at Cape Canaveral Space Force Station and NASA’s Kennedy Space Center, located next to one another in Florida. Launches from other US-licensed spaceports, primarily Vandenberg Space Force Base, California, and Rocket Lab’s base at Māhia Peninsula in New Zealand, are also on the rise.

These numbers represent rockets that reached low-Earth orbit. We didn’t include test flights of SpaceX’s Starship rocket in the chart because all of its launches have intentionally flown on suborbital trajectories.

In the second chart, we break down the payload upmass to orbit from SpaceX, other US companies, China, Russia, and other international launch providers.

Launch rates are on a clear upward trend, while SpaceX has launched 86 percent of the world’s total payload mass to orbit since the beginning of 2024. Credit: Stephen Clark/Ars Technica/BryceTech

Will it continue?

It’s a good bet that payload upmass will continue to rise in the coming years, with heavy cargo heading to orbit to further expand SpaceX’s Starlink communications network and build out new megaconstellations from Amazon, China, and others. The US military’s Golden Dome missile defense shield will also have a ravenous appetite for rockets to get it into space.

SpaceX’s Starship megarocket could begin flying to low-Earth orbit next year, and if it does, SpaceX’s preeminence in delivering mass to orbit will remain assured. Starship’s first real payloads will likely be SpaceX’s next-generation Starlink satellites. These larger, heavier, more capable spacecraft will launch 60 at a time on Starship, further stretching SpaceX’s lead in the upmass war.

But Starship’s arrival will come at the expense of the workhorse Falcon 9, which lacks the capacity to haul the next-gen Starlinks to orbit. “This year and next year I anticipate will be the highest Falcon launch rates that we will see,” said Stephanie Bednarek, SpaceX’s vice president of commercial sales, at an industry conference in July.

SpaceX is on pace for between 165 and 170 Falcon 9 launches this year, with 144 flights already in the books for 2025. Last year’s total for Falcon 9 and Falcon Heavy was 134 missions. SpaceX has not announced how many Falcon 9 and Falcon Heavy launches it plans for next year.

Starship is designed to be fully and rapidly reusable, eventually enabling multiple flights per day. But that’s still a long way off, and it’s unknown how many years it might take for Starship to surpass the Falcon 9’s proven launch tempo.

A Starship rocket and Super Heavy booster lift off from Starbase, Texas. Credit: SpaceX

In any case, with Starship’s heavy-lifting capacity and upgraded next-gen satellites, SpaceX could match an entire year’s worth of new Starlink capacity with just two fully loaded Starship flights. Starship will be able to deliver 60 times more Starlink capacity to orbit than a cluster of satellites riding on a Falcon 9.

There’s no reason to believe SpaceX will be satisfied with simply keeping pace with today’s Starlink growth rate. There are emerging market opportunities in connecting satellites with smartphones, space-based computer processing and data storage, and military applications.

Other companies have medium-to-heavy rockets that are either new to the market or soon to debut. These include Blue Origin’s New Glenn, now set to make its second test flight in the coming days, with a reusable booster designed to facilitate a rapid-fire launch cadence.

Despite all of the newcomers, most satellite operators see a shortage of launch capacity on the commercial market. “The industry is likely to remain supply-constrained through the balance of the decade,” wrote Caleb Henry, director of research at the industry analysis firm Quilty Space. “That could pose a problem for some of the many large constellations on the horizon.”

United Launch Alliance’s Vulcan rocket, Rocket Lab’s Neutron, Stoke Space’s Nova, Relativity Space’s Terran R, and Firefly Aerospace and Northrop Grumman’s Eclipse are among the other rockets vying for a bite at the launch apple.

“Whether or not the market can support six medium to heavy lift launch providers from the US alone—plus Starship—is an open question, but for the remainder of the decade launch demand is likely to remain high, presenting an opportunity for one or more new players to establish themselves in the pecking order,” Henry wrote in a post on Quilty’s website.

China’s space program will need more rockets, too. That nation’s two megaconstellations, known as Guowang and Qianfan, will have thousands of satellites requiring a significant uptick on Chinese launches.

Taking all of this into account, the demand curve for access to space is sure to continue its upward trajectory. How companies meet this demand, and with how many discrete departures from Earth, isn’t quite as clear.

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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NASA’s next Moonship reaches last stop before launch pad

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The Orion spacecraft, which will fly four people around the Moon, arrived inside the cavernous Vehicle Assembly Building at NASA’s Kennedy Space Center in Florida late Thursday night, ready to be stacked on top of its rocket for launch early next year.

The late-night transfer covered about 6 miles (10 kilometers) from one facility to another at the Florida spaceport. NASA and its contractors are continuing preparations for the Artemis II mission after the White House approved the program as an exception to work through the ongoing government shutdown, which began on October 1.

The sustained work could set up Artemis II for a launch opportunity as soon as February 5 of next year. Astronauts Reid Wiseman, Victor Glover, Christina Koch, and Jeremy Hansen will be the first humans to fly on the Orion spacecraft, a vehicle that has been in development for nearly two decades. The Artemis II crew will make history on their 10-day flight by becoming the first people to travel to the vicinity of the Moon since 1972.

Where things stand

The Orion spacecraft, developed by Lockheed Martin, has made several stops at Kennedy over the last few months since leaving its factory in May.

First, the capsule moved to a fueling facility, where technicians filled it with hydrazine and nitrogen tetroxide propellants, which will feed Orion’s main engine and maneuvering thrusters on the flight to the Moon and back. In the same facility, teams loaded high-pressure helium and ammonia coolant into Orion propulsion and thermal control systems.

The next stop was a nearby building where the Launch Abort System was installed on the Orion spacecraft. The tower-like abort system would pull the capsule away from its rocket in the event of a launch failure. Orion stands roughly 67 feet (20 meters) tall with its service module, crew module, and abort tower integrated together.

Teams at Kennedy also installed four ogive panels to serve as an aerodynamic shield over the Orion crew capsule during the first few minutes of launch.

The Orion spacecraft, with its Launch Abort System and ogive panels installed, is seen last month inside the Launch Abort System Facility at Kennedy Space Center, Florida. Credit: NASA/Frank Michaux

It was then time to move Orion to the Vehicle Assembly Building (VAB), where a separate team has worked all year to stack the elements of NASA’s Space Launch System rocket. In the coming days, cranes will lift the spacecraft, weighing 78,000 pounds (35 metric tons), dozens of stories above the VAB’s center aisle, then up and over the transom into the building’s northeast high bay to be lowered atop the SLS heavy-lift rocket.

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Starship will soon fly over towns and cities, but will dodge the biggest ones

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Starship’s next chapter will involve launching over Florida and returning over Mexico.

SpaceX’s Starship vehicle is encased in plasma as it reenters the atmosphere over the Indian Ocean on its most recent test flight in August. Credit: SpaceX

Some time soon, perhaps next year, SpaceX will attempt to fly one of its enormous Starship rockets from low-Earth orbit back to its launch pad in South Texas. A successful return and catch at the launch tower would demonstrate a key capability underpinning Elon Musk’s hopes for a fully reusable rocket.

In order for this to happen, SpaceX must overcome the tyranny of geography. Unlike launches over the open ocean from Cape Canaveral, Florida, rockets departing from South Texas must follow a narrow corridor to steer clear of downrange land masses.

All 10 of the rocket’s test flights so far have launched from Texas toward splashdowns in the Indian or Pacific Oceans. On these trajectories, the rocket never completes a full orbit around the Earth, but instead flies an arcing path through space before gravity pulls it back into the atmosphere.

If Starship’s next two test flights go well, SpaceX will likely attempt to send the soon-to-debut third-generation version of the rocket all the way to low-Earth orbit. The Starship V3 vehicle will measure 171 feet (52.1 meters) tall, a few feet more than Starship’s current configuration. The entire rocket, including its Super Heavy booster, will have a height of 408 feet (124.4 meters).

Starship, made of stainless steel, is designed for full reusability. SpaceX has already recovered and reflown Super Heavy boosters, but won’t be ready to recover the rocket’s Starship upper stage until next year, at the soonest.

That’s one of the next major milestones in Starship’s development after achieving orbital flight. SpaceX will attempt to bring the ship home to be caught back at the launch site by the launch tower at Starbase, Texas, located on the southernmost section of the Texas Gulf Coast near the US-Mexico border.

It was always evident that flying a Starship from low-Earth orbit back to Starbase would require the rocket to fly over Mexico and portions of South Texas. The rocket launches to the east over the Gulf of Mexico, so it must approach Starbase from the west when it comes in for a landing.

New maps published by the Federal Aviation Administration show where the first Starships returning to Texas may fly when they streak through the atmosphere.

Paths to and from orbit

The FAA released a document Friday describing SpaceX’s request to update its government license for additional Starship launch and reentry trajectories. The document is a draft version of a “tiered environmental assessment” examining the potential for significant environmental impacts from the new launch and reentry flight paths.

The federal regulator said it is evaluating potential impacts in aviation emissions and air quality, noise and noise-compatible land use, hazardous materials, and socioeconomics. The FAA concluded the new flight paths proposed by SpaceX would have “no significant impacts” in any of these categories.

SpaceX’s Starship rocket shortly before splashing into the Indian Ocean in August. Credit: SpaceX

The environmental review is just one of several factors the FAA considers when deciding whether to approve a new commercial launch or reentry license. According to the FAA, the other factors are public safety issues (such as overflight of populated areas and payload contents), national security or foreign policy concerns, and insurance requirements.

The FAA didn’t make a statement on any public safety and foreign policy concerns with SpaceX’s new trajectories, but both issues may come into play as the company seeks approval to fly Starship over Mexican towns and cities uprange from Starbase.

The regulator’s licensing rules state that a commercial launch and reentry should each pose no greater than a 1 in 10,000 chance of harming or killing a member of the public not involved in the mission. The risk to any individual should not exceed 1 in 1 million.

So, what’s the danger? If something on Starship fails, it could disintegrate in the atmosphere. Surviving debris would rain down to the ground, as it did over the Turks and Caicos Islands after two Starship launch failures earlier this year. Two other Starship flights ran into problems once in space, tumbling out of control and breaking apart during reentry over the Indian Ocean.

The most recent Starship flight last month was more successful, with the ship reaching its target in the Indian Ocean for a pinpoint splashdown. The splashdown had an error of just 3 meters (10 feet), giving SpaceX confidence in returning future Starships to land.

This map shows Starship’s proposed reentry corridor. Credit: Federal Aviation Administration

One way of minimizing the risk to the public is to avoid flying over large metropolitan areas, and that’s exactly what SpaceX and the FAA are proposing to do, at least for the initial attempts to bring Starship home from orbit. A map of a “notional” Starship reentry flight path shows the vehicle beginning its reentry over the Pacific Ocean, then passing over Baja California and soaring above Mexico’s interior near the cities of Hermosillo and Chihuahua, each with a population of roughly a million people.

The trajectory would bring Starship well north of the Monterrey metro area and its 5.3 million residents, then over the Rio Grande Valley near the Texas cities of McAllen and Brownsville. During the final segment of Starship’s return trajectory, the vehicle will begin a vertical descent over Starbase before a final landing burn to slow it down for the launch pad’s arms to catch it in midair.

In addition to Monterrey, the proposed flight path dodges overflights of major US cities like San Diego, Phoenix, and El Paso, Texas.

Let’s back up

Setting up for this reentry trajectory requires SpaceX to launch Starship into an orbit with exactly the right inclination, or angle to the equator. There are safety constraints for SpaceX and the FAA to consider here, too.

All of the Starship test flights to date have launched toward the east, threading between South Florida and Cuba, south of the Bahamas, and north of Puerto Rico before heading over the North Atlantic Ocean. For Starship to target just the right orbit to set up for reentry, the rocket must fly in a slightly different direction over the Gulf.

Another map released by the FAA shows two possible paths Starship could take. One of the options goes to the southeast between Mexico’s Yucatan Peninsula and the western tip of Cuba, then directly over Jamaica as the rocket accelerated into orbit over the Caribbean Sea. The other would see Starship departing South Texas on a northeasterly path and crossing over North Florida before reaching the Atlantic Ocean.

While both trajectories fly over land, they avoid the largest cities situated near the flight path. For example, the southerly route misses Cancun, Mexico, and the northerly path flies between Jacksonville and Orlando, Florida. “Orbital launches would primarily be to low inclinations with flight trajectories north or south of Cuba that minimize land overflight,” the FAA wrote in its draft environmental assessment.

The FAA analyzed two launch trajectory options for future orbital Starship test flights. Credit: Federal Aviation Administration

The proposed launch and reentry trajectories would result in temporary airspace closures, the FAA said. This could force delays or rerouting of anywhere from seven to 400 commercial flights for each launch, according to the FAA’s assessment.

Launch airspace closures are already the norm for Starship test flights. The FAA concluded that the reentry path over Mexico would require the closure of a swath of airspace covering more than 4,200 miles. This would affect up to 200 more commercial airplane flights during each Starship mission. Eventually, the FAA aims to shrink the airspace closures as SpaceX demonstrates improved reliability with Starship test flights.

Eventually, SpaceX will move some flights of Starship to Florida’s Space Coast, where rockets can safely launch in many directions over the Atlantic. By then, SpaceX aims to be launching Starships at a regular cadence—first, multiple flights per month, then per week, and then per day.

This will enable all of the things SpaceX wants to do with Starship. Chief among these goals is to fly Starships to Mars. Before then, SpaceX must master orbital refueling. NASA also has a contract with SpaceX to build Starships to land astronauts on the Moon’s south pole.

But all of that assumes SpaceX can routinely launch and recover Starships. That’s what engineers hope to soon prove they can do.

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NASA closing its original repository for Columbia artifacts to tours

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NASA is changing the way that its employees come in contact with, and remember, one of its worst tragedies.

In the wake of the 2003 loss of the space shuttle Columbia and its STS-107 crew, NASA created a program to use the orbiter’s debris for research and education at Kennedy Space Center in Florida. Agency employees were invited to see what remained of the space shuttle as a powerful reminder as to why they had to be diligent in their work. Access to the Columbia Research and Preservation Office, though, was limited as a result of its location and related logistics.

To address that and open up the experience to more of the workforce at Kennedy, the agency has quietly begun work to establish a new facility.

“The room, titled Columbia Learning Center (CLC), is a whole new concept,” a NASA spokesperson wrote in an email. “There are no access requirements; anyone at NASA Kennedy can go in any day of the week and stay as long as they like. The CLC will be available whenever employees need the inspiration and message for generations to come.”

Debris depository

On February 1, 2003, Columbia was making its way back from a 16-day science mission in Earth orbit when the damage that it suffered during its launch resulted in the orbiter breaking apart over East Texas. Instead of landing at Kennedy as planned, Columbia fell to the ground in more than 85,000 pieces.

The tragedy claimed the lives of commander Rick Husband, pilot Willie McCool, mission specialists David Brown, Kalpana Chawla, Michael Anderson, and Laurel Clark, and payload specialist Ilan Ramon of Israel.

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As preps continue, it’s looking more likely NASA will fly the Artemis II mission

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NASA’s existing architecture still has a limited shelf life, and the agency will probably have multiple options for transporting astronauts to and from the Moon in the 2030s. A decision on the long-term future of SLS and Orion isn’t expected until the Trump administration’s nominee for NASA administrator, Jared Isaacman, takes office after confirmation by the Senate.

So, what is the plan for SLS?

There are different degrees of cancellation options. The most draconian would be an immediate order to stop work on Artemis II preparations. This is looking less likely than it did a few months ago and would come with its own costs. It would cost untold millions of dollars to disassemble and dispose of parts of Artemis II’s SLS rocket and Orion spacecraft. Canceling multibillion-dollar contracts with Boeing, Northrop Grumman, and Lockheed Martin would put NASA on the hook for significant termination costs.

Of course, these liabilities would be less than the $4.1 billion NASA’s inspector general estimates each of the first four Artemis missions will cost. Most of that money has already been spent for Artemis II, but if NASA spends several billion dollars on each Artemis mission, there won’t be much money left over to do other cool things.

Other options for NASA might be to set a transition point when the Artemis program would move off of the Space Launch System rocket, and perhaps even the Orion spacecraft, and switch to new vehicles.

Looking down on the Space Launch System for Artemis II. Credit: NASA/Frank Michaux

Another possibility, which seems to be low-hanging fruit for Artemis decision-makers, could be to cancel the development of a larger Exploration Upper Stage for the SLS rocket. If there are a finite number of SLS flights on NASA’s schedule, it’s difficult to justify the projected $5.7 billion cost of developing the upgraded Block 1B version of the Space Launch System. There are commercial options available to replace the rocket’s Boeing-built Exploration Upper Stage, as my colleague Eric Berger aptly described in a feature story last year.

For now, it looks like NASA’s orange behemoth has a little life left in it. All the hardware for the Artemis II mission has arrived at the launch site in Florida.

The Trump administration will release its fiscal-year 2026 budget request in the coming weeks. Maybe then NASA will also have a permanent administrator, and the veil will lift over the White House’s plans for Artemis.

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

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A good sign

The readiness of the Orion crew capsule, where the four Artemis II astronauts will live during their voyage around the Moon, is driving NASA’s schedule for the mission. Officially, Artemis II is projected to launch in September of next year, but there’s little chance of meeting that schedule.

At the beginning of this year, NASA officials ruled out any opportunity to launch Artemis II in 2024 due to several technical issues with the Orion spacecraft. Several of these issues are now resolved, but NASA has not released any meaningful updates on the most significant problem.

This problem involves the Orion spacecraft’s heat shield. During atmospheric reentry at the end of the uncrewed Artemis I test flight in 2022, the Orion capsule’s heat shield eroded and cracked in unexpected ways, prompting investigations by NASA engineers and an independent panel.

NASA’s Orion heat shield inquiry ran for nearly two years. The investigation has wrapped up, two NASA officials said last month, but they declined to discuss any details of the root cause of the heat shield issue or the actions required to resolve the problem on Artemis II.

These corrective options ranged from doing nothing to changing the Orion spacecraft’s reentry angle to mitigate heating or physically modifying the Artemis II heat shield. In the latter scenario, NASA would have to disassemble the Orion spacecraft, which is already put together and is undergoing environmental testing at Kennedy Space Center. This would likely delay the Artemis II launch by a couple of years.

In August, NASA’s top human exploration official told Ars that the agency would hold off on stacking the SLS rocket until engineers had a good handle on the heat shield problem. There are limits to how long the solid rocket boosters can remain stacked vertically. The joints connecting each segment of the rocket motors are certified for one year. This clock doesn’t actually start ticking until NASA stacks the next booster segments on top of the lowermost segments.

However, NASA waived this rule on Artemis I when the boosters were stacked nearly two years before the successful launch.

A NASA spokesperson told Ars on Wednesday that the agency had nothing new to share on the Orion heat shield or what changes, if any, are required for the Artemis II mission. This information should be released before the end of the year, she said. At the same time, NASA could announce a new target launch date for Artemis II at the end of 2025, or more likely in 2026.

But because NASA gave the “go” for SLS stacking now, it seems safe to rule out any major hardware changes on the Orion heat shield for Artemis II.

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

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The central piece of NASA’s second Space Launch System rocket arrived at Kennedy Space Center in Florida this week. Agency officials intend to start stacking the towering launcher in the next couple of months for a mission late next year carrying a team of four astronauts around the Moon.

The Artemis II mission, officially scheduled for September 2025, will be the first voyage by humans to the vicinity of the Moon since the last Apollo lunar landing mission in 1972. NASA astronauts Reid Wiseman, Victor Glover, Christina Koch, and Canadian mission specialist Jeremy Hansen will ride the SLS rocket away from Earth, then fly around the far side of the Moon and return home inside NASA’s Orion spacecraft.

“The core is the backbone of SLS, and it’s the backbone of the Artemis mission,” said Matthew Ramsey, NASA’s mission manager for Artemis II. “We’ve been waiting for the core to get here because all the integrated tests and checkouts that we do have to have the core stage. It has the flight avionics that drive the whole system. The boosters are also important, but the core is really the backbone for Artemis. So it’s a big day.”

The core stage rolled off of NASA’s Pegasus barge at Kennedy early Wednesday, following a weeklong ocean voyage from New Orleans, where Boeing builds the rocket under contract to NASA.

Ramsey told Ars that ground teams hope to begin stacking the rocket’s two powerful solid rocket boosters on NASA’s mobile launcher platform in September. Each booster, supplied by Northrop Grumman, is made of five segments with pre-packed solid propellant and a nose cone. All the pieces for the SLS boosters are at Kennedy and ready for stacking, Ramsey said.

The SLS upper stage, built by United Launch Alliance, is also at the Florida launch site. Now, the core stage is at Kennedy. In August or September, NASA plans to deliver the two remaining elements of the SLS rocket to Florida. These are the adapter structures that will connect the core stage to the upper stage, and the upper stage to the Orion spacecraft.

A heavy-duty crane inside the cavernous Vehicle Assembly Building (VAB) will hoist each segment of the SLS boosters into place on the launch platform. Once the boosters are fully stacked, ground teams will lift the 212-foot (65-meter) core stage vertical in the transfer aisle running through the center of the VAB. A crane will then lower the core stage between the boosters. That could happen as soon as December, according to Ramsey.

Then comes the launch vehicle stage adapter, the upper stage, the Orion stage adapter, and finally, the Orion spacecraft itself.

Moving toward operations

NASA’s inspector general reported in 2022 that NASA’s first four Artemis missions will each cost $4.1 billion. Subsequent documents, including a Government Accountability Office report last year, suggest the expendable SLS core stage is responsible for at least a quarter of the cost for each Artemis flight.

The core stage for Artemis II is powered by four hydrogen-fueled RS-25 engines produced by Aerojet Rocketdyne. Two of the reusable engines for Artemis II have flown on the space shuttle, and the other two RS-25s were built in the shuttle era but never flew. Each SLS launch will put the core stage and its engines in the Atlantic Ocean.

Steve Wofford, who manages the stages office for the SLS program at NASA’s Marshall Space Flight Center, told Ars there are “no major configuration differences” between the core stages for Artemis I and Artemis II. The only minor differences involve instrumentation that NASA wanted on Artemis I to measure pressures, accelerations, vibrations, temperatures, and other parameters on the first flight of the Space Launch System.

“We are still working off some flight observations that we made on Artemis I, but no showstoppers,” Wofford said. “On the first article, the test flight, Artemis I, we really loaded it up. That’s a golden opportunity to learn as much as you can about the vehicle and the flight regime, and anchor all your models… As you progress, you need less and less of that. So Core Stage 2 will have less development flight instrumentation than Core Stage 1, and then Core Stage 3 will have less still.”

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

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SpaceX's Starship tower (left) at Launch Complex 39A dwarfs the launch pad for the Falcon 9 rocket (right). — Enlarge / SpaceX’s Starship tower (left) at Launch Complex 39A dwarfs the launch pad for the Falcon 9 rocket (right).

There are a couple of ways to read the announcement from the Federal Aviation Administration that it’s kicking off a new environmental review of SpaceX’s plan to launch the most powerful rocket in the world from Florida.

The FAA said on May 10 that it plans to develop an Environmental Impact Statement (EIS) for SpaceX’s proposal to launch Starships from NASA’s Kennedy Space Center in Florida. The FAA ordered this review after SpaceX updated the regulatory agency on the projected Starship launch rate and the design of the ground infrastructure needed at Launch Complex 39A (LC-39A), the historic launch pad once used for Apollo and Space Shuttle missions.

Dual environmental reviews

At the same time, the US Space Force is overseeing a similar EIS for SpaceX’s proposal to take over a launch pad at Cape Canaveral Space Force Station, a few miles south of LC-39A. This launch pad, designated Space Launch Complex 37 (SLC-37), is available for use after United Launch Alliance’s last Delta rocket lifted off there in April.

On the one hand, these environmental reviews often take a while and could cloud Elon Musk’s goal of having Starship launch sites in Florida ready for service by the end of 2025. “A couple of years would not be a surprise,” said George Nield, an aerospace industry consultant and former head of the FAA’s Office of Commercial Space Transportation.

Another way to look at the recent FAA and Space Force announcements of pending environmental reviews is that SpaceX finally appears to be cementing its plans to launch Starship from Florida. These plans have changed quite a bit in the last five years.

The environmental reviews will culminate in a decision on whether to approve SpaceX’s proposals for Starship launches at LC-39A and SLC-37. The FAA will then go through a separate licensing process, similar to the framework used to license the first three Starship test launches from South Texas.

NASA has contracts with SpaceX worth more than $4 billion to develop a human-rated version of Starship to land astronauts on the Moon on the first two Artemis lunar landing flights later this decade. To do that, SpaceX must stage a fuel depot in low-Earth orbit to refuel the Starship lunar lander before it heads for the Moon. It will take a series of Starship tanker flights—perhaps 10 to 15—to fill the depot with cryogenic propellants.

Launching that many Starships over the course of a month or two will require SpaceX to alternate between at least two launch pads. NASA and SpaceX officials say the best way to do this is by launching Starships from one pad in Texas and another in Florida.

Earlier this week, Ars spoke with Lisa Watson-Morgan, who manages NASA’s human-rated lunar lander program. She was at Kennedy Space Center this week for briefings on the Starship lander and a competing lander from Blue Origin. One of the topics, she said, was the FAA’s new environmental review before Starship can launch from LC-39A.

“I would say we’re doing all we can to pull the schedule to where it needs to be, and we are working with SpaceX to make sure that their timeline, the EIS timeline, and NASA’s all work in parallel as much as we can to achieve our objectives,” she said. “When you’re writing it down on paper just as it is, it looks like there could be some tight areas, but I would say we’re collectively working through it.”

Officially, SpaceX plans to perform a dress rehearsal for the Starship lunar landing in late 2025. This will be a full demonstration, with refueling missions, an uncrewed landing of Starship on the lunar surface, then a takeoff from the Moon, before NASA commits to putting people on Starship on the Artemis III mission, currently slated for September 2026.

So you can see that schedules are already tight for the Starship lunar landing demonstration if SpaceX activates launch pads in Florida late next year.

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

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

Boeing, falcon heavy, Kennedy Space Center, launch, Space, spacex, X-37b / DJ Henderson / December 11, 2023

SpaceX's Falcon Heavy rocket stands on Launch Complex 39A in Florida, hours before its scheduled liftoff with the military's X-37B spaceplane. — Enlarge / SpaceX’s Falcon Heavy rocket stands on Launch Complex 39A in Florida, hours before its scheduled liftoff with the military’s X-37B spaceplane.

Trevor Mahlmann/Ars Technica

CAPE CANAVERAL, Florida—A SpaceX Falcon Heavy rocket is poised for launch as soon as Tuesday night from the Kennedy Space Center in Florida, and the US military’s mysterious X-37B spaceplane is fastened atop the heavy-lifter for a ride into orbit.

Although the Space Force is keeping details about the military spaceplane’s flight under wraps, we know it’s heading into an unusual orbit, probably significantly higher than the X-37B’s previous sojourns that stayed within a few hundred miles of Earth’s surface.

SpaceX’s launch team called off a launch attempt Monday night “due to a ground side issue” and reset for another launch opportunity as soon as Tuesday night at 8: 14pm EST (01: 14 UTC). When it lifts off, the Falcon Heavy will light 27 kerosene-fueled engines to power the rocket off its launch pad overlooking the Atlantic coastline.

You can watch the launch using SpaceX’s live video feed on X, the social media platform, or if you prefer YouTube, third-party streams are available from Spaceflight Now and NASASpaceflight.

The exact altitude the X-37B will be flying through is unclear, but hobbyists and amateur sleuths who use open source information to reconstruct trajectories of top-secret military spacecraft suggest the Falcon Heavy will haul the winged vehicle into an orbit that could stretch tens of thousands of miles above the planet.

What’s more, the Falcon Heavy will apparently take a flight path toward the northeast from Florida’s Space Coast, then ultimately release the X-37B on a trajectory that will take it over Earth’s polar regions. This is a significant departure from the flight profile for the military spaceplane’s six previous missions, which all flew to space on smaller rockets than the Falcon Heavy.

In a statement, the Space Force said this flight of the X-37B is focused on “a wide range of test and experimentation objectives.” Flying in “new orbital regimes” is among the test objectives, military officials said.

“It seems to me like it might be a much higher orbit that it’s going to,” said Brian Weeden, director of program planning for the Secure World Foundation, which promotes sustainable and peaceful uses of outer space. “Otherwise, I don’t know why they would use a Falcon Heavy, which is a pretty big thing.”

Covering more ground

The X-37B spaceplane has attracted a lot of attention and speculation since its first mission in 2010. Across multiple administrations, Pentagon officials have consistently walked a narrow line between acknowledging the existence of the spaceplane, and divulging limited information about its general purpose, while treating some details with the utmost secrecy. The military does not talk about where in space it flies. With a few exceptions, defense officials haven’t publicly discussed specifics of what the X-37B carries into orbit.

The military has two Boeing-built X-37B spaceplanes, or Orbital Test Vehicles, in its inventory. They are reusable and designed to launch inside the payload fairing of a conventional rocket, spend multiple years in space with the use of solar power, and then return to Earth for a landing on a three-mile-long runway, either at Vandenberg Space Force Base in California or at NASA’s Kennedy Space Center in Florida.

It resembles a miniature version of NASA’s retired space shuttle orbiter, with wings, deployable landing gear, and black thermal protection tiles to shield its belly from the scorching heat of reentry. It measures 29 feet (about 9 meters) long, roughly a quarter of the length of NASA’s space shuttle, and it doesn’t carry astronauts. The X-37B has a cargo bay inside the fuselage for payloads, with doors that open after launch and close before landing.

The Space Force made a surprise announcement on November 8 that the next flight of the X-37B, sometimes called OTV-7, would launch on a SpaceX Falcon Heavy rocket. All six of the spaceplane’s past flights launched on smaller rockets, either United Launch Alliance’s Atlas V or SpaceX’s Falcon 9.

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