launch

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Pentagon contract figures show ULA’s Vulcan rocket is getting more expensive

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A SpaceX Falcon Heavy rocket with NASA’s Psyche spacecraft launches from NASA’s Kennedy Space Center in Florida on October 13, 2023. Credit: Chandan Khanna/AFP via Getty Images

The launch orders announced Friday comprise the second batch of NSSL Phase 3 missions the Space Force has awarded to SpaceX and ULA.

It’s important to remember that these prices aren’t what ULA or SpaceX would charge a commercial satellite customer. The US government pays a premium for access to space. The Space Force, the National Reconnaissance Office, and NASA don’t insure their launches like a commercial customer would do. Instead, government agencies have more insight into their launch contractors, including inspections, flight data reviews, risk assessments, and security checks. Government missions also typically get priority on ULA and SpaceX’s launch schedules. All of this adds up to more money.

A heavy burden

Four of the five launches awarded to SpaceX Friday will use the company’s larger Falcon Heavy rocket, according to Lt. Col. Kristina Stewart at Space Systems Command. One will fly on SpaceX’s workhorse Falcon 9. This is the first time a majority of the Space Force’s annual launch orders has required the lift capability of a Falcon Heavy, with three Falcon 9 booster cores combining to heave larger payloads into space.

All versions of ULA’s Vulcan rocket use a single core booster, with varying numbers of strap-on solid-fueled rocket motors to provide extra thrust off the launch pad.

Here’s a breakdown of the seven new missions assigned to SpaceX and ULA:

• USSF-149: Classified payload on a SpaceX Falcon 9 from Florida

• USSF-63: Classified payload on a SpaceX Falcon Heavy from Florida

• USSF-155: Classified payload SpaceX Falcon Heavy from Florida

• USSF-205: WGS-12 communications satellite on a SpaceX Falcon Heavy from Florida

• NROL-86: Classified payload on a SpaceX Falcon Heavy from Florida

• USSF-88: GPS IIIF-4 navigation satellite on a ULA Vulcan VC2S (two solid rocket boosters) from Florida

• NROL-88: Classified payload on a ULA Vulcan VC4S (four solid rocket boosters) from Florida

Pentagon contract figures show ULA’s Vulcan rocket is getting more expensive Read More »

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Removing these 50 objects from orbit would cut danger from space junk in half

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China, on the other hand, frequently abandons upper stages in orbit. China launched 21 of the 26 hazardous new rocket bodies over the last 21 months, each averaging more than 4 metric tons (8,800 pounds). Two more came from US launchers, one from Russia, one from India, and one from Iran.

This trend is likely to continue as China steps up deployment of two megaconstellations—Guowang and Thousand Sails—with thousands of communications satellites in low-Earth orbit. Launches of these constellations began last year. The Guowang and Thousand Sails satellites are relatively small and likely capable of maneuvering out of the way of space debris, although China has not disclosed their exact capabilities.

However, most of the rockets used for Guowang and Thousand Sails launches have left their upper stages in orbit. McKnight said nine upper stages China has abandoned after launching Guowang and Thousand Sails satellites will stay in orbit for more than 25 years, violating the international guidelines.

It will take hundreds of rockets to fully populate China’s two major megaconstellations. The prospect of so much new space debris is worrisome, McKnight said.

“In the next few years, if they continue the same trend, they’re going to leave well over 100 rocket bodies over the 25-year rule if they continue to deploy these constellations,” he said. “So, the trend is not good.”

There are technical and practical reasons not to deorbit an upper stage at the end of its mission. Some older models of Chinese rockets simply don’t have the capability to reignite their engines in space, leaving them adrift after deploying their payloads. Even if a rocket flies with a restartable upper stage engine, a launch provider must reserve enough fuel for a deorbit burn. This eats into the rocket’s payload capacity, meaning it must carry fewer satellites.

“We know the Chinese have the capability to not leave rocket bodies,” McKnight said. One example is the Long March 5 rocket, which launched three times with batches of Guowang satellites. On those missions, the Long March 5 flew with an upper stage called the YZ-2, a high-endurance maneuvering vehicle that deorbits itself at the end of its mission. The story isn’t so good for launches using other types of rockets.

“With the other ones, they always leave a rocket body,” McKnight said. “So, they have the capability to do sustainable practices, but on average, they do not.”

A Japanese H-IIA upper stage imaged by Astroscale’s ADRAS-J spacecraft last year. Credit: Astroscale

Since 2000, China has accumulated more dead rocket mass in long-lived orbits than the rest of the world combined, according to McKnight. “But now we’re at a point where it’s actually kind of accelerating in the last two years as these constellations are getting deployed.”

Removing these 50 objects from orbit would cut danger from space junk in half Read More »

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Blue Origin aims to land next New Glenn booster, then reuse it for Moon mission

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“We fully intend to recover the New Glenn first stage on this next launch.”

New Glenn lifts off on its debut flight on January 16, 2025. Credit: Blue Origin

There’s a good bit riding on the second launch of Blue Origin’s New Glenn rocket.

Most directly, the fate of a NASA science mission to study Mars’ upper atmosphere hinges on a successful launch. The second flight of Blue Origin’s heavy-lifter will send two NASA-funded satellites toward the red planet to study the processes that drove Mars’ evolution from a warmer, wetter world to the cold, dry planet of today.

A successful launch would also nudge Blue Origin closer to winning certification from the Space Force to begin launching national security satellites.

But there’s more on the line. If Blue Origin plans to launch its first robotic Moon lander early next year—as currently envisioned—the company needs to recover the New Glenn rocket’s first stage booster. Crews will again dispatch Blue Origin’s landing platform into the Atlantic Ocean, just as they did for the first New Glenn flight in January.

The debut launch of New Glenn successfully reached orbit, a difficult feat for the inaugural flight of any rocket. But the booster fell into the Atlantic Ocean after three of the rocket’s engines failed to reignite to slow down for landing. Engineers identified seven changes to resolve the problem, focusing on what Blue Origin calls “propellant management and engine bleed control improvements.”

Relying on reuse

Pat Remias, Blue Origin’s vice president of space systems development, said Thursday that the company is confident in nailing the landing on the second flight of New Glenn. That launch, with NASA’s next set of Mars probes, is likely to occur no earlier than November from Cape Canaveral Space Force Station, Florida.

“We fully intend to recover the New Glenn first stage on this next launch,” Remias said in a presentation at the International Astronautical Congress in Sydney. “Fully intend to do it.”

Blue Origin, owned by billionaire Jeff Bezos, nicknamed the booster stage for the next flight “Never Tell Me The Odds.” It’s not quite fair to say the company’s leadership has gone all-in with their bet that the next launch will result in a successful booster landing. But the difference between a smooth touchdown and another crash landing will have a significant effect on Bezos’ Moon program.

That’s because the third New Glenn launch, penciled in for no earlier than January of next year, will reuse the same booster flown on the upcoming second flight. The payload on that launch will be Blue Origin’s first Blue Moon lander, aiming to become the largest spacecraft to reach the lunar surface. Ars has published a lengthy feature on the Blue Moon lander’s role in NASA’s effort to return astronauts to the Moon.

“We will use that first stage on the next New Glenn launch,” Remias said. “That is the intent. We’re pretty confident this time. We knew it was going to be a long shot [to land the booster] on the first launch.”

A long shot, indeed. It took SpaceX 20 launches of its Falcon 9 rocket over five years before pulling off the first landing of a booster. It was another 15 months before SpaceX launched a previously flown Falcon 9 booster for the first time.

With New Glenn, Blue’s engineers hope to drastically shorten the learning curve. Going into the second launch, the company’s managers anticipate refurbishing the first recovered New Glenn booster to launch again within 90 days. That would be a remarkable accomplishment.

Dave Limp, Blue Origin’s CEO, wrote earlier this year on social media that recovering the booster on the second New Glenn flight will “take a little bit of luck and a lot of excellent execution.”

On September 26, Blue Origin shared this photo of the second New Glenn booster on social media.

Blue Origin’s production of second stages for the New Glenn rocket has far outpaced manufacturing of booster stages. The second stage for the second flight was test-fired in April, and Blue completed a similar static-fire test for the third second stage in August. Meanwhile, according to a social media post written by Limp last week, the body of the second New Glenn booster is assembled, and installation of its seven BE-4 engines is “well underway” at the company’s rocket factory in Florida.

The lagging production of New Glenn boosters, known as GS1s (Glenn Stage 1s), is partly by design. Blue Origin’s strategy with New Glenn has been to build a small number of GS1s, each of which is more expensive and labor-intensive than SpaceX’s Falcon 9. This approach counts on routine recoveries and rapid refurbishment of boosters between missions.

However, this strategy comes with risks, as it puts the booster landings in the critical path for ramping up New Glenn’s launch rate. At one time, Blue aimed to launch eight New Glenn flights this year; it will probably end the year with two.

Laura Maginnis, Blue Origin’s vice president of New Glenn mission management, said last month that the company was building a fleet of “several boosters” and had eight upper stages in storage. That would bode well for a quick ramp-up in launch cadence next year.

However, Blue’s engineers haven’t had a chance to inspect or test a recovered New Glenn booster. Even if the next launch concludes with a successful landing, the rocket could come back to Earth with some surprises. SpaceX’s initial development of Falcon 9 and Starship was richer in hardware, with many boosters in production to decouple successful landings from forward progress.

Blue Moon

All of this means a lot is riding on an on-target landing of the New Glenn booster on the next flight. Separate from Blue Origin’s ambitions to fly many more New Glenn rockets next year, a good recovery would also mean an earlier demonstration of the company’s first lunar lander.

The lander set to launch on the third New Glenn mission is known as Blue Moon Mark 1, an unpiloted vehicle designed to robotically deliver up to 3 metric tons (about 6,600 pounds) of cargo to the lunar surface. The spacecraft will have a height of about 26 feet (8 meters), taller than the lunar lander used for NASA’s Apollo astronaut missions.

The first Blue Moon Mark 1 is funded from Blue Origin’s coffers. It is now fully assembled and will soon ship to NASA’s Johnson Space Center in Houston for vacuum chamber testing. Then, it will travel to Florida’s Space Coast for final launch preparations.

“We are building a series, not a singular lander, but multiple types and sizes and scales of landers to go to the Moon,” Remias said.

The second Mark 1 lander will carry NASA’s VIPER rover to prospect for water ice at the Moon’s south pole in late 2027. Around the same time, Blue will use a Mark 1 lander to deploy two small satellites to orbit the Moon, flying as low as a few miles above the surface to scout for resources like water, precious metals, rare Earth elements, and helium-3 that could be extracted and exploited by future explorers.

A larger lander, Blue Moon Mark 2, is in an earlier stage of development. It will be human-rated to land astronauts on the Moon for NASA’s Artemis program.

Blue Origin’s Blue Moon MK1 lander, seen in the center, is taller than NASA’s Apollo lunar lander, currently the largest spacecraft to have landed on the Moon. Blue Moon MK2 is even larger, but all three landers are dwarfed in size by SpaceX’s Starship. Credit: Blue Origin

NASA’s other crew-rated lander will be derived from SpaceX’s Starship rocket. But Starship and Blue Moon Mark 2 are years away from being ready to accommodate a human crew, and both require orbital cryogenic refueling—something never before attempted in space—to transit out to the Moon.

This has led to a bit of a dilemma at NASA. China is also working on a lunar program, eyeing a crew landing on the Moon by 2030. Many experts say that, as of today, China is on pace to land astronauts on the Moon before the United States.

Of course, 12 US astronauts walked on the Moon in the Apollo program. But no one has gone back since 1972, and NASA and China are each planning to return to the Moon to stay.

One way to speed up a US landing on the Moon might be to use a modified version of Blue Origin’s Mark 1 lander, Ars reported Thursday.

If this is the path NASA takes, the stakes for the next New Glenn launch and landing will soar even higher.

Photo of Stephen Clark

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.

Blue Origin aims to land next New Glenn booster, then reuse it for Moon mission Read More »

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Another setback for Firefly Aerospace’s beleaguered rocket program

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Alpha’s track record

The booster destroyed Monday was slated to fly on the seventh launch of Firefly’s Alpha rocket, an expendable, two-stage launch vehicle capable of placing a payload of a little over 2,200 pounds, or a metric ton, into low-Earth orbit.

This upcoming launch was supposed to be the Alpha rocket’s return to flight after an in-flight failure in April, when the upper stage’s engine shut down before the rocket could reach orbit and deploy its satellite payload.

But engineers traced the cause of the failure to the first stage, which ruptured milliseconds after stage separation, sending out a blast wave that damaged the upper stage engine. Investigators concluded the most likely cause of the rupture was thermal damage from a phenomenon known as plume-induced flow separation. This occurs when a rocket plume expands at higher altitudes, creating conditions that, in some cases, can draw the hot exhaust plume farther up the vehicle.

The Alpha rocket flew a higher angle of attack on the April launch than it did on prior missions, exposing one side of the rocket to more heating from the recirculated engine exhaust plume. At stage separation, the thermal damage led to the booster’s structural failure. Firefly said it would add a thicker thermal protection barrier to the booster for future missions and reduce the angle of attack during key phases of flight.

Firefly announced last month that it received clearance from the Federal Aviation Administration to resume Alpha launches.

The rocket already had a mixed record heading into this year. Firefly has only achieved two fully successful missions in six launches of the Alpha rocket. Two missions put their payloads into off-target orbits, and two Alpha launches—the rocket’s debut in 2021 and the flight in April—failed to reach orbit at all.

Another setback for Firefly Aerospace’s beleaguered rocket program Read More »

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US intel officials “concerned” China will soon master reusable launch

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“They have to have on-orbit refueling because they don’t access space as frequently as we do.”

File photo of a reusable Falcon 9 booster moments before landing on a recent flight at Cape Canaveral Space Force Station, Florida. Credit: SpaceX

SpaceX scored its 500th landing of a Falcon 9 first stage booster on an otherwise routine flight earlier this month, sending 28 Starlink communications satellites into orbit. Barring any unforeseen problems, SpaceX will mark the 500th re-flight of a Falcon first stage later this year.

A handful of other US companies, including Blue Origin, Rocket Lab, Relativity Space, and Stoke Space, are on the way to replicating or building on SpaceX’s achievements in recycling rocket parts. These launch providers are racing a medley of Chinese rocket builders to become the second company to land and reuse a first stage booster.

But it will be many years—perhaps a decade or longer—until anyone else matches the kinds of numbers SpaceX is racking up in the realm of reusable rockets. SpaceX’s dominance in this field is one of the most important advantages the United States has over China as competition between the two nations extends into space, US Space Force officials said Monday.

“It’s concerning how fast they’re going,” said Brig. Gen. Brian Sidari, the Space Force’s deputy chief of space operations for intelligence. “I’m concerned about when the Chinese figure out how to do reusable lift that allows them to put more capability on orbit at a quicker cadence than currently exists.”

Taking advantage

China has used 14 different types of rockets on its 56 orbital-class missions this year, and none have flown more than 11 times. Eight US rocket types have cumulatively flown 142 times, with 120 of those using SpaceX’s workhorse Falcon 9. Without a reusable rocket, China must maintain more rocket companies to sustain a launch rate of just one-third to one-half that of the United States.

This contrasts with the situation just four years ago, when China outpaced the United States in orbital rocket launches. The growth in US launches has been a direct result of SpaceX’s improvements to launch at a higher rate, an achievement primarily driven by the recovery and reuse of Falcon 9 boosters and payload fairings. Last month, SpaceX flew one of its Falcon 9 boosters for the 30th time and set a record at nine days for the shortest turnaround between flights of the same booster in March.

“They’ve put more satellites on orbit,” Sidari said, referring to China. “They still do not compare to the US, but it is concerning once they figure out that reusable lift. The other one is the megaconstellations. They’ve seen how the megaconstellations provide capability to the US joint force and the West, and they’re mimicking it. So, that does concern me, how fast they’re going, but we’ll see. It’s easier said than done. They do have to figure it out, and they do have some challenges that we haven’t dealt with.”

One of those challenges is China’s continued reliance on expendable rockets. This has made it more important for China to make “game-changing” advancements in other areas, according to Chief Master Sgt. Ron Lerch, the Space Force’s senior enlisted advisor for intelligence.

Lerch pointed to the recent refueling of a Chinese satellite in geosynchronous orbit, more than 22,000 miles (nearly 36,000 kilometers) over the equator. China’s Shijian-21 and Shijian-25 satellites, known as SJ-21 and SJ-25 for short, came together on July 2 and have remained together ever since, according to open source orbital tracking data.

No one has refueled a spacecraft so far from Earth before. SJ-25 appears to be the refueler for SJ-21, a Chinese craft capable of latching onto other satellites and towing them to different orbits. Chinese officials say SJ-21 is testing “space debris mitigation” techniques, but US officials have raised concerns that China is testing a counter-space weapon that could sidle up to an American or allied satellite and take control of it.

Lerch said satellite refueling is more important to China than it is to the United States. With refueling, China can achieve a different kind of reuse in space while the government waits for reusable rockets to enter service.

“They have to have on-orbit refueling as a capability because they don’t access space as frequently as we do,” Lerch said Monday at the Air Force Association’s Air, Space, and Cyber Conference. “When it comes to replenishing our toolkit, getting more capability (on orbit) and reconstitution, having reusable launch is what affords us that ability, and the Chinese don’t have that. So, pursuing things like refueling on orbit, it is game-changing for them.”

The Nebula 1 rocket from China’s Deep Blue Aerospace just before attempting to land on a vertical takeoff, vertical landing test flight last year. Credit: Deep Blue Aerospace

SpaceX’s rapid-fire cadence is pivotal for a number of US national security programs. The Pentagon uses SpaceX’s Starlink satellites, which take up most of the Falcon 9 launch capacity, for commercial-grade global connectivity. SpaceX’s Starshield satellite platform, derived from the Starlink design, has launched in stacks of up to 22 spacecraft on a single Falcon 9 to deploy a constellation of hundreds of all-seeing spy satellites for the National Reconnaissance Office. The most recent batch of these Starshield satellites launched Monday.

Cheaper, readily available launch services will also be critical to the Pentagon’s aspirations to construct a missile shield to defend against attacks on the US homeland. Sensors and interceptors for the military’s planned Golden Dome missile defense system will be scattered throughout low-Earth orbit.

SpaceX’s inventory of Falcon 9 rockets has enabled the Space Force to move closer to realizing on-demand launch services. On two occasions within the last year, the Space Force asked SpaceX to launch a GPS navigation satellite with just a few months of lead time to prepare for the mission. With a fleet of reusable rockets at the ready, SpaceX delivered.

Meanwhile, China recently started deploying its own satellite megaconstellations. Chinese officials claim these new satellite networks will be used for Internet connectivity. That may be so, but Pentagon officials worry China can use them for other purposes, just as the Space Force is doing with Starlink, Starshield, and other programs.

Copycats in space

Lerch mentioned two other recent Chinese actions in space that have his attention. One is the launch of five Tongxin Jishu Shiyan (TJS) satellites, or what China calls communication technology test satellites, into geosynchronous orbit since January, something Lerch called “highly unusual.” Chinese authorities released (rather interesting) patches for four of these TJS satellites, suggesting they are part of a family of spacecraft.

“More importantly, these spacecraft sitting at GEO (geosynchronous orbit) are not supposed to be sliding all around the GEO belt,” Lerch said. “But the history of these experimental spacecraft have shown that that’s exactly what they do, which is very uncharacteristic for a system that’s supposed to be providing satellite communications.”

US officials believe China uses at least some of the TJS satellites for missile warning or spy missions. TJS satellites filling the role of a reconnaissance mission might have enormous umbrella-like reflectors to try to pick up communication signals transmitted by foreign forces, such as those of the United States.

A modified Long March 7 rocket carrying the Yaogan 45 satellite lifts off from the Wenchang Space Launch Site on September 9, 2025, in Wenchang, Hainan Province of China. Credit: Luo Yunfei/China News Service/VCG via Getty Images

China also launched a spy satellite called Yaogan 45 into a peculiar orbit earlier this month. (Yaogan is a cover name for China’s military spy satellites.) Yaogan 45 is a remote sensing platform, Lerch said, but it’s flying much higher than a typical Earth-imaging satellite. Instead of orbiting a few hundred miles above the Earth, Yaogan 45 circles at an altitude of some 4,660 miles (7,500 kilometers).

“That, alone, is very interesting,” Lerch said.

But US intelligence officials believe there’s more to the story. China launched the country’s first two communications satellites into a so-called medium-Earth orbit, or MEO, last year. These satellites are the first in a network called Smart Skynet.

“It looks like a year ago they started to put the infrastructure at MEO to be able to move around data, and then a year later, the Chinese are now putting remote sensing capability at MEO as well,” Lerch said. “That’s interesting, and that starts to paint a picture that they value remote sensing to the point where they want resiliency in layers of it.”

China launched a satellite named Yaogan 41 into geosynchronous orbit in 2023 with a sharp-eyed telescope with enough sensitivity to track car-sized objects on the ground and at sea. From its perch in geosynchronous orbit, Yaogan 41 will provide China’s military with a continuous view of the Indo-Pacific region. A single satellite in low-Earth orbit offers only fleeting views.

Some of this may sound familiar if you follow what the US military and the National Reconnaissance Office are doing with their satellites.

“Our military power has served as a bit of an open book, and adversaries have watched and observed us for years,” said Lt. Gen. Max Pearson, the Air Force’s deputy chief of staff for intelligence.

China’s military has “observed how we fight, the techniques we use, the weapons systems we have,” Pearson said. “When you combine that with intellectual property theft that has fueled a lot of their modernization, they have deliberately developed and modernized to counter our American way of war.”

Photo of Stephen Clark

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.

US intel officials “concerned” China will soon master reusable launch Read More »

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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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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.

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

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Northrop Grumman’s new spacecraft is a real chonker

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What happens when you use a SpaceX Falcon 9 rocket to launch Northrop Grumman’s Cygnus supply ship? A record-setting resupply mission to the International Space Station.

The first flight of Northrop’s upgraded Cygnus spacecraft, called Cygnus XL, is on its way to the international research lab after launching Sunday evening from Cape Canaveral Space Force Station, Florida. This mission, known as NG-23, is set to arrive at the ISS early Wednesday with 10,827 pounds (4,911 kilograms) of cargo to sustain the lab and its seven-person crew.

By a sizable margin, this is the heaviest cargo load transported to the ISS by a commercial resupply mission. NASA astronaut Jonny Kim will use the space station’s Canadian-built robotic arm to capture the cargo ship on Wednesday, then place it on an attachment port for crew members to open hatches and start unpacking the goodies inside.

A bigger keg

The Cygnus XL spacecraft looks a lot like Northrop’s previous missions to the station. It has a service module manufactured at the company’s factory in Northern Virginia. This segment of the spacecraft provides power, propulsion, and other necessities to keep Cygnus operating in orbit.

The most prominent features of the Cygnus cargo freighter are its circular, fan-like solar arrays and an aluminum cylinder called the pressurized cargo module that bears some resemblance to a keg of beer. This is the element that distinguishes the Cygnus XL from earlier versions of the Cygnus supply ship.

The cargo module is 5.2 feet (1.6 meters) longer on the Cygnus XL. The full spacecraft is roughly the size of two Apollo command modules, according to Ryan Tintner, vice president of civil space systems at Northrop Grumman. Put another way, the volume of the cargo section is equivalent to two-and-a-half minivans.

“The most notable thing on this mission is we are debuting the Cygnus XL configuration of the spacecraft,” Tintner said. “It’s got 33 percent more capacity than the prior Cygnus spacecraft had. Obviously, more may sound like better, but it’s really critical because we can deliver significantly more science, as well as we’re able to deliver a lot more cargo per launch, really trying to drive down the cost per kilogram to NASA.”

A SpaceX Falcon 9 rocket ascends to orbit Sunday after launching from Cape Canaveral Space Force Station, Florida, carrying Northrop Grumman’s Cygnus XL cargo spacecraft toward the International Space Station. Credit: Manuel Mazzanti/NurPhoto via Getty Images

Cargo modules for Northrop’s Cygnus spacecraft are built by Thales Alenia Space in Turin, Italy, employing a similar design to the one Thales used for several of the space station’s permanent modules. Officials moved forward with the first Cygnus XL mission after the preceding cargo module was damaged during shipment from Italy to the United States earlier this year.

Northrop Grumman’s new spacecraft is a real chonker Read More »

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Pentagon begins deploying new satellite network to link sensors with shooters

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“This is the first time we’ll have a space layer fully integrated into our warfighting operations.”

A SpaceX Falcon 9 rocket lifts off from Vandenberg Space Force Base, California, with a payload of 21 data-relay satellites for the US military’s Space Development Agency. Credit: SpaceX

The first 21 satellites in a constellation that could become a cornerstone for the Pentagon’s Golden Dome missile-defense shield successfully launched from California Wednesday aboard a SpaceX Falcon 9 rocket.

The Falcon 9 took off from Vandenberg Space Force Base, California, at 7: 12 am PDT (10: 12 am EDT; 14: 12 UTC) and headed south over the Pacific Ocean, heading for an orbit over the poles before releasing the 21 military-owned satellites to begin several weeks of activations and checkouts.

These 21 satellites will boost themselves to a final orbit at an altitude of roughly 600 miles (1,000 kilometers). The Pentagon plans to launch 133 more satellites over the next nine months to complete the build-out of the Space Development Agency’s first-generation, or Tranche 1, constellation of missile-tracking and data-relay satellites.

“We had a great launch today for the Space Development Agency, putting this array of space vehicles into orbit in support of their revolutionary new architecture,” said Col. Ryan Hiserote, system program director for the Space Force’s assured access to space launch execution division.

Over the horizon

Military officials have worked for six years to reach this moment. The Space Development Agency (SDA) was established during the first Trump administration, which made plans for an initial set of demonstration satellites that launched a couple of years ago. In 2022, the Pentagon awarded contracts for the first 154 operational spacecraft. The first batch of 21 data-relay satellites built by Colorado-based York Space Systems is what went up Wednesday.

“Back in 2019, when the SDA was stood up, it was to do two things. One was to make sure that we can do beyond line of sight targeting, and the other was to pace the threat, the emerging threat, in the missile-warning and missile-tracking domain. That’s what the focus has been,” said Gurpartap “GP” Sandhoo, the SDA’s acting director.

Secretary of the Air Force Troy Meink and Sen. Kevin Cramer (R-N.D.) pose with industry and government teams in front of the Space Development’s first 21 operational satellites at Vandenberg Space Force Base, California. Cramer is one the most prominent backers of the Golden Dome program in the US Senate. Credit: US Air Force/Staff Sgt. Daekwon Stith

Historically, the military communications and missile-warning networks have used a handful of large, expensive satellites in geosynchronous orbit some 22,000 miles (36,000 kilometers) above the Earth. This architecture was devised during the Cold War and is optimized for nuclear conflict and intercontinental ballistic missiles.

For example, the military’s ultra-hardened Advanced Extremely High Frequency satellites in geosynchronous orbit are designed to operate through an electromagnetic pulse and nuclear scintillation. The Space Force’s missile-warning satellites are also in geosynchronous orbit, with infrared sensors tuned to detect the heat plume of a missile launch.

The problem? Those satellites cost more than $1 billion a pop. They’re also vulnerable to attack from a foreign adversary. Pentagon officials say the SDA’s satellite constellation, officially called the Proliferated Warfighter Space Architecture, is tailored to detect and track more modern threats, such as smaller missiles and hypersonic weapons carrying conventional warheads. It’s easier for these missiles to evade the eyes of older early warning satellites.

What’s more, the SDA’s fleet in low-Earth orbit will have numerous satellites. Losing one or several satellites to an attack would not degrade the constellation’s overall capability. The SDA’s new relay satellites cost between $14 and $15 million each, according to Sandhoo. The total cost of the first tranche of 154 operational satellites totals approximately $3.1 billion.

Multi-mission satellites

These satellites will not only detect and track ballistic and hypersonic missile launches; they will also transmit signals between US forces using an existing encrypted tactical data link network known as Link 16. This UHF system is used by NATO and other US allies to allow military aircraft, ships, and land forces to share tactical information through text messages, pictures, data, and voice communication in near real time, according to the SDA’s website.

Up to now, Link 16 radios were ubiquitous on fighter jets, helicopters, naval vessels, and missile batteries. But they had a severe limitation. Link 16 was only able to close a radio link with a clear line of sight. The Space Development Agency’s satellites will change that, providing direct-to-weapon connectivity from sensors to shooters on Earth’s surface, in the air, and in space.

The relay satellites, which the SDA calls the transport layer, are also equipped with Ka-band and laser communication terminals for higher-bandwidth connectivity.

“What the transport layer does is it extends beyond the line of sight,” Sandhoo said. “Now, you’re able to talk not only to within a couple of miles with your Link 16 radios, (but) we can use space to, let’s say, go from Hawaii out to Guam using those tactical radios, using a space layer.”

The Space Development Agency’s “Tranche 1” architecture includes 154 operational satellites, 126 for data relay and 28 for missile tracking. With this illustration, the SDA does its best to show how the complex architecture is supposed to work. Credit: Space Development Agency

Another batch of SDA relay satellites will launch next month, and more will head to space in November. In all, it will take 10 launches to fully deploy the SDA’s Tranche 1 constellation. Six of those missions will carry data-relay satellites, and four will carry satellites with sensors to detect and track missile launches. The Pentagon selected several contractors to build the satellites, so the military is not reliant on a single company. The builders of the SDA’s operational satellites include York, Lockheed Martin, Northrop Grumman, and L3Harris.

“We will increase coverage as we get the rest of those launches on orbit,” said Michael Eppolito, the SDA’s acting deputy director.

The satellites will connect with one another using inter-satellite laser links, creating a mesh network with sufficient range to provide regional communications, missile warning, and targeting coverage over the Western Pacific beginning in 2027. US Indo-Pacific Command, which oversees military operations in this region, is slated to become the first combatant command to take up use of the SDA’s satellite constellation.

This is not incidental. US officials see China as the nation’s primary strategic threat, and Indo-Pacific Command would be on the front lines of any future conflict between Chinese and US forces. The SDA has contracts in place for more than 270 second-generation, or Tranche 2, satellites, to further expand the network’s reach. There’s also a third generation in the works, but the Pentagon has paused part of the SDA’s Tranche 3 program to evaluate other architectures, including one offered by SpaceX.

Teaching tactical operators to use the new capabilities offered by the SDA’s satellite fleet could be just as challenging as building the network itself. To do this, the Pentagon plans to put soldiers, sailors, airmen, and marines through “warfighter immersion” training beginning next year. This training will allow US forces to “get used to using space from this construct,” Sandhoo said.

“This is different than how it has been done in the past,” Sandhoo said. “This is the first time we’ll have a space layer actually fully integrated into our warfighting operations.”

The SDA’s satellite architecture is a harbinger for what’s to come with the Pentagon’s Golden Dome system, a missile-defense shield for the US homeland proposed by President Donald Trump in an executive order in January. Congress authorized a down payment on Golden Dome in July, the first piece of funding for what the White House says will cost $175 billion over the next three years.

Golden Dome, as currently envisioned, will require thousands of satellites in low-Earth orbit to track missile launches and space-based interceptors to attempt to shoot them down. The Trump administration hasn’t said how much of the shield might be deployed by the end of 2028, or what the entire system might eventually cost.

But the capabilities of the SDA’s satellites will lay the foundation for any regional or national missile-defense shield. Therefore, it seems likely that the military will incorporate the SDA network into Golden Dome, which, at least at first, is likely to consist of technologies already in space or nearing launch. Apart from the Space Development Agency’s architecture in low-Earth orbit (LEO), the Space Force was already developing a new generation of missile-warning satellites to replace aging platforms in geosynchronous orbit (GEO), plus a fleet of missile-warning satellites to fly at a midrange altitude between LEO and GEO.

Air Force Gen. Gregory Guillot, commander of US Northern Command, said in April that Golden Dome “for the first time integrates multiple layers into one system that allows us to detect, track, and defeat multiple types of threats that affect us in different domains.

“So, while a lot of the components and the requirements were there in the past, this is the first time that it’s all tied together in one system,” he said.

Photo of Stephen Clark

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.

Pentagon begins deploying new satellite network to link sensors with shooters Read More »

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Lull in Falcon Heavy missions opens window for SpaceX to build new landing pads

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SpaceX’s goal for this year is 170 Falcon 9 launches, and the company is on pace to come close to this target. Most Falcon 9 launches carry SpaceX’s own Starlink broadband satellites into orbit. The FAA’s environmental approval opens the door for more flights from SpaceX’s busiest launch pad.

But launch pad availability is not the only hurdle limiting how many Falcon 9 flights can take off in a year. There’s also the rate of production for Falcon 9 upper stages, which are new on each flight, and the time it takes for each vessel in SpaceX’s fleet of drone ships (one in California, two in Florida) to return to port with a recovered booster and redeploy back to sea again for the next mission. SpaceX lands Falcon 9 boosters on offshore drone ships after most of its launches and only brings the rocket back to an onshore landing on missions carrying lighter payloads to orbit.

When a Falcon 9 booster does return to landing on land, it targets one of SpaceX’s recovery zones at military-run spaceports in Florida and California. SpaceX’s landing zone at Vandenberg Space Force Base in California is close to the Falcon 9 launch pad there.

The Space Force wants SpaceX, and potentially other future reusable rocket companies, to replicate the side-by-side launch and landing pads at Cape Canaveral.

To do that, the FAA also gave the green light Wednesday for SpaceX to construct and operate a new rocket landing zone at SLC-40 and conduct up to 34 first-stage booster landings there each year. The landing zone will consist of a 280-foot diameter concrete pad surrounded by a 60-foot-wide gravel apron. The landing zone’s broadest diameter, including the apron, will measure 400 feet.

The location of SpaceX’s new rocket landing pad is shown with the red circle, approximately 1,000 feet northeast of the Falcon 9 rocket’s launch pad at Space Launch Complex-40. Credit: Google Maps/Ars Technica

SpaceX is in an earlier phase of planning for a Falcon landing pad at historic Launch Complex-39A at NASA’s Kennedy Space Center, just a few miles north of SLC-40. SpaceX uses LC-39A as a launch pad for most Falcon 9 crew launches, all Falcon Heavy missions, and, in the future, flights of the company’s gigantic next-generation rocket, Starship. SpaceX foresees Starship as a replacement for Falcon 9 and Falcon Heavy, but the company’s continuing investment in Falcon-related infrastructure shows the workhorse rocket will stick around for a while.

Lull in Falcon Heavy missions opens window for SpaceX to build new landing pads Read More »

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Rocket Report: SpaceX achieved daily launch this week; ULA recovers booster

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Firefly Aerospace reveals why its Alpha booster exploded after launch in April.

Starship and its Super Heavy booster ascend through a clear sky over Starbase, Texas, on Tuesday evening. A visible vapor cone enveloped the rocket as it passed through maximum aerodynamic pressure and the speed of sound. Credit: Stephen Clark/Ars Technica

Welcome to Edition 8.08 of the Rocket Report! What a week it’s been for SpaceX. The company completed its first successful Starship test flight in nearly a year, and while it wasn’t perfect, it sets up SpaceX for far more ambitious tests ahead. SpaceX’s workhorse rocket, the Falcon 9, launched six times since our last edition of the Rocket Report. Many of these missions were noteworthy in their own right, including the launch of the US military’s X-37B spaceplane, an upgraded Dragon capsule to boost the International Space Station to a higher orbit, and the record 30th launch and landing of a flight-proven Falcon 9 booster. All told, that’s seven SpaceX launches in seven days.

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

Firefly announces cause of Alpha launch failure. Firefly Aerospace closed the investigation into the failure of one of its Alpha rockets during an April mission for Lockheed Martin and received clearance from the FAA to resume launches, Payload reports. The loss of the launch vehicle was a dark cloud hanging over the company’s otherwise successful IPO this month. The sixth flight of Firefly’s Alpha rocket launched in April from Vandenberg Space Force Base, California, and failed when its first stage booster broke apart milliseconds after stage separation. This created a shockwave that destroyed the engine nozzle extension on the second stage, damaging the engine before the second stage ran out of propellant seconds before it attained orbital velocity. Both stages ultimately fell into the Pacific Ocean.

Too much stress … Investigators concluded that “plume induced flow separation” caused the failure. The phenomenon occurs when a rocket’s exhaust disrupts airflow around the vehicle in flight. In this case, Firefly said the rocket was flying at a higher angle of attack than prior missions, which resulted in the flow separation and created intense heat that broke the first stage apart just after it jettisoned from the second stage. Firefly will increase heat shielding on the first stage of the rocket and fly at reduced angles of attack on future missions. Alpha has now launched six times since 2021, with only two complete successes. Firefly said it was working on setting a date for the seventh Alpha launch. (submitted by EllPeaTea)

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ESA books a ticket on European launchers. The European Space Agency has awarded launch service contracts to Avio and Isar Aerospace under its Flight Ticket Initiative, European Spaceflight reports. Announced in October 2023, the Flight Ticket Initiative is a program run jointly by ESA and the European Union that offers subsidized flight opportunities for European companies and organizations seeking to demonstrate new satellite technologies in orbit. The initiative is part of ESA’s strategy to foster the continent’s commercial space industry, offering institutional funding to support satellite and launch companies. Avio won contracts to launch three small European space missions as secondary payloads on Vega C rockets flying into low-Earth orbit. Isar Aerospace will launch two small satellite missions to orbit for European companies.

No other options … Avio and Isar Aerospace were the obvious contenders for the Flight Ticket Initiative from a pool of five European companies eligible for launch awards. The other companies, PLD Space, Orbex, and Rocket Factory Augsburg, haven’t launched their orbital-class rockets yet. Avio, based in Italy, builds the now-operational Vega C rocket, and Germany’s Isar Aerospace launched its first Spectrum rocket earlier this year, but it failed to reach orbit. Avio’s selection replaces Arianespace, which was originally part of the Flight Ticket Initiative. Arianespace was previously responsible for marketing and sales for the Vega rocket, but ESA transferred its Flight Ticket Initiative eligibility to Avio following its split from Arianespace. (submitted by EllPeaTea)

Canadian rocket company ready for launch. NordSpace is preparing to launch its 6-meter tall Taiga rocket from Newfoundland, CBC reports. It will be a suborbital launch, meaning it won’t orbit Earth, but NordSpace says the launch will be the first of a Canadian commercial rocket from a Canadian commercial spaceport. The rocket is powered by a 3D-printed liquid-fueled engine and is a stepping stone to an orbital-class rocket NordSpace is developing called Tundra, scheduled to debut in 2027. The smaller Taiga rocket will launch partially fueled and fire its engine for approximately 60 seconds, according to NordSpace.

Newfoundland to space … The launch site, called the Atlantic Spaceport Complex, is located on the Atlantic coast near the town of St. Lawrence, Newfoundland. It will have two launch pads, one for suborbital flights like Taiga, and another for orbital missions by the Tundra rocket and other launch vehicles from US and European companies. The Taiga launch is scheduled no earlier than Friday morning at 5: 00 am EDT (09: 00 UTC). NordSpace says it is a “fully privately funded and managed initiative crucial for Canada to build a space launch capability that supports our security, economy, and sovereignty.” (submitted by Matthew P)

SpaceX’s reuse idea isn’t so dumb after all. A Falcon 9 rocket launched early Thursday from Kennedy Space Center, Florida, with another batch of Starlink Internet satellites. These types of missions launch multiple times per week, but this flight was special. The first stage of the Falcon 9, designated Booster 1067, launched and landed on drone ship in the Atlantic Ocean, completing its 30th flight to space and back, Ars reports. This is a new record for a reusable orbital-class booster stage and comes less than 24 hours after a preceding SpaceX launch from Florida that marked the 400th Falcon 9 landing on a drone ship since the first offshore recovery in 2016.

30 going for 40 … SpaceX is now aiming for at least 40 launches per Falcon 9 first stage, four times as many flights as the company’s original target for Falcon 9 booster reuse. Many people in the industry were skeptical about SpaceX’s approach to reuse. In the mid-2010s, both the European and Japanese space agencies were looking to develop their next generation of rockets. In both cases, Europe with the Ariane 6 and Japan with the H3, the space agencies opted for traditional, expendable rockets instead of pushing toward reuse. In the United States, the main competitor to SpaceX has historically been United Launch Alliance. Their reaction to SpaceX’s plan to reuse first stages a decade ago was dismissive. ULA dubbed its plan to reuse just the engine section of its Vulcan rocket “Smart Reuse” a few years ago. But ULA hasn’t even attempted to recover the engines from the Vulcan core stage yet, and reuse is still at least several years away.

Russia nears debut of Soyuz-5 rocket. In recent comments to the Russian state-run media service TASS, the chief of Roscosmos said the country’s newest rocket, the Soyuz-5, should take flight for the first time before the end of this year, Ars reports. “Yes, we are planning for December,” said Dmitry Bakanov, the director of Roscosmos, Russia’s main space corporation. “Everything is in place.” According to the report, translated for Ars by Rob Mitchell, the debut launch of Soyuz-5 will mark the first of several demonstration flights, with full operational service not expected to begin until 2028. It will launch from the Baikonur spaceport in Kazakhstan.

Breaking free of Ukraine … From an innovation standpoint, the Soyuz-5 vehicle does not stand out. It has been a decade in the making and is fully expendable, unlike a lot of newer medium-lift rockets coming online in the next several years. However, for Russia, this is an important advancement because it seeks to break some of the country’s dependency on Ukraine for launch technology. The new rocket is also named Irtysh, a river that flows through Russia and Kazakhstan. The rocket has been in development since 2016 and largely repurposes older technology. But for Russia, a key advantage is that it takes rocket elements formerly made in Ukraine and now manufactures them in Russia.

SpaceX launches mission to reboost the ISS. SpaceX completed its 33rd cargo delivery to the International Space Station (ISS) early Monday, when a Dragon supply ship glided to an automated docking with more than 5,000 pounds of scientific experiments and provisions for the lab’s seven-person crew, Ars reports. The resupply flight is part of the normal rotation of cargo and crew missions that keep the space station operating, but this one carries something new. What’s different with this mission is a new rocket pack mounted inside the Dragon spacecraft’s rear trunk section. In the coming weeks, SpaceX and NASA will use this first-of-its-kind propulsion system to begin boosting the altitude of the space station’s orbit.

A rocket on a rocket … SpaceX engineers installed two small Draco rocket engines in the trunk of the Dragon spacecraft. The thrusters have their own dedicated propellant tanks and will operate independently of 16 other Draco thrusters used to maneuver Dragon on its journey to the ISS. When NASA says it’s the right time, SpaceX controllers will command the Draco thrusters to ignite and gently accelerate the massive 450-ton space station. All told, the reboost kit can add about 20 mph, or 9 meters per second, to the space station’s already-dizzying speed. Maintaining the space station’s orbit has previously been the responsibility of Russia.

X-37B rides with SpaceX again. The US military’s reusable winged spaceship rocketed back into orbit from Florida on August 21 atop a SpaceX rocket, kicking off a mission that will, among other things, demonstrate how future spacecraft can navigate without relying on GPS signals, Ars reports. The core of the navigation experiment is what the Space Force calls the “world’s highest performing quantum inertial sensor ever used in space.” The spaceplane also hosts a laser inter-satellite communications demo. This is the eighth flight of the X-37B spaceplane, and the third to launch with SpaceX.

Back to LEO … This mission launched on a Falcon 9 rocket into low-Earth orbit (LEO) a few hundred miles above the Earth. This marks a return to LEO after the previous X-37B mission flew on a Falcon Heavy rocket into a much higher orbit. Many of the spaceplane’s payloads have been classified, but officials typically identify a handful of unclassified experiments flying on each X-37B mission. Past X-37B missions have also deployed small satellites into orbit before returning to Earth for a runway landing at Kennedy Space Center, Florida, or Vandenberg Space Force Base, California.

Rocket Lab cuts the ribbon on Neutron launch pad. Launch Complex 3, the Virginia Spaceport Authority’s Mid-Atlantic Regional Spaceport and home to Rocket Lab’s newest reusable rocket, Neutron, is now complete and celebrated its official opening Thursday, WAVY-TV reports. Officials said Launch Complex 3 is ready to bring the largest orbital launch capacity in the spaceport’s history with Neutron, Rocket Lab’s reusable launch vehicle, a medium-lift vehicle capable of launching 33,000 pounds (15 metric tons) to space for commercial constellations, national security, and interplanetary missions.

Not budging … “We’re trying as hard as we can to get this on the pad by the end of the year and get it away,” said Peter Beck, Rocket Lab’s founder and CEO. Beck is holding to his hope the Neutron rocket will be ready to fly in the next four months, but time is running out to make this a reality. The Neutron rocket will be Rocket Lab’s second orbital-class launch vehicle after the Electron, which can place payloads of several hundred pounds in orbit. Electron has a launch pad in Virginia, too, but most Electron rockets take off from New Zealand.

Starship completes a largely successful test flight. SpaceX launched the 10th test flight of the company’s Starship rocket Tuesday evening, sending the stainless steel spacecraft halfway around the world to an on-target splashdown in the Indian Ocean, Ars reports. The largely successful mission for the world’s largest rocket was an important milestone for SpaceX’s Starship program after months of repeated setbacks, including three disappointing test flights and a powerful explosion on the ground that destroyed the ship that engineers were originally readying for this launch.

Lessons to learn … For the first time, SpaceX engineers received data on the performance of the ship’s upgraded heat shield and control flaps during reentry back into the atmosphere. The three failed Starship test flights to start the year ended before the ship reached reentry. Elon Musk, SpaceX’s founder and CEO, has described developing a durable, reliable heat shield as the most pressing challenge for making Starship a fully and rapidly reusable rocket. But there were lessons to learn from Tuesday’s flight. A large section of the ship transitioned from its original silver color to a rusty hue of orange and brown by the time it reached the Indian Ocean. Officials didn’t immediately address this or say whether it was anticipated.

ULA recovering boosters, too. United Launch Alliance decided to pull four strap-on solid rocket boosters from the Atlantic Ocean after their use on the company’s most recent launch. Photos captured by Florida photographer Jerry Pike showed a solid rocket motor casing on a ship just off the coast of Cape Canaveral. Tory Bruno, ULA’s president and CEO, wrote on X that the booster was one of four flown on the USSF-106 mission earlier this month, which marked the third flight of ULA’s Vulcan rocket and the first with a US national security payload.

A GEM from the sea … The boosters, built by Northrop Grumman, are officially called Graphite Epoxy Motors, or GEMs. They jettison from the Vulcan rocket less than two minutes after liftoff and fall into the ocean. They’re not designed for reuse, but ULA decided to recover this set of four from the Atlantic for inspections. The company also raised from the sea two motors from the previous Vulcan launch last year after one of them suffered a nozzle failure during launch. Bruno wrote on X that “performance and ballistics were spot on” with all four boosters from the more recent USSF-106 mission, but that engineers decided to go ahead and recover them to close out a “nice data set” from inspections of now six recovered motors—two from last year and four this year.

Next three launches

Aug. 30: Falcon 9 | Starlink 17-7 | Vandenberg Space Force Base, California | 03: 09 UTC

Aug. 31: Falcon 9 | Starlink 10-14 | Cape Canaveral Space Force Station, Florida | 11: 15 UTC

Sept. 3:  Falcon 9 | Starlink 17-8 | Vandenberg Space Force Base, California | 02: 33 UTC

Photo of Stephen Clark

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.

Rocket Report: SpaceX achieved daily launch this week; ULA recovers booster Read More »

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Under pressure after setbacks, SpaceX’s huge rocket finally goes the distance

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The ship made it all the way through reentry, turned to a horizontal position to descend through scattered clouds, then relit three of its engines to flip back to a vertical orientation for the final braking maneuver before splashdown.

Things to improve on

There are several takeaways from Tuesday’s flight that will require some improvements to Starship, but these are more akin to what officials might expect from a rocket test program and not the catastrophic failures of the ship that occurred earlier this year.

One of the Super Heavy booster’s 33 engines prematurely shut down during ascent. This has happened before, and while it didn’t affect the booster’s overall performance, engineers will investigate the failure to try to improve the reliability of SpaceX’s Raptor engines, each of which can generate more than a half-million pounds of thrust.

Later in the flight, cameras pointed at one of the ship’s rear flaps showed structural damage to the back of the wing. It wasn’t clear what caused the damage, but super-heated plasma burned through part of the flap as the ship fell deeper into the atmosphere. Still, the flap remained largely intact and was able to help control the vehicle through reentry and splashdown.

“We’re kind of being mean to this Starship a little bit,” Huot said on SpaceX’s live webcast. “We’re really trying to put it through the paces and kind of poke on what some of its weak points are.”

Small chunks of debris were also visible peeling off the ship during reentry. The origin of the glowing debris wasn’t immediately clear, but it may have been parts of the ship’s heat shield tiles. On this flight, SpaceX tested several different tile designs, including ceramic and metallic materials, and one tile design that uses “active cooling” to help dissipate heat during reentry.

A bright flash inside the ship’s engine bay during reentry also appeared to damage the vehicle’s aft skirt, the stainless steel structure that encircles the rocket’s six main engines.

“That’s not what we want to see,” Huot said. “We just saw some of the aft skirt just take a hit. So we’ve got some visible damage on the aft skirt. We’re continuing to reenter, though. We are intentionally stressing the ship as we go through this, so it is not guaranteed to be a smooth ride down to the Indian Ocean.

“We’ve removed a bunch of tiles in kind of critical places across the vehicle, so seeing stuff like that is still valuable to us,” he said. “We are trying to kind of push this vehicle to the limits to learn what its limits are as we design our next version of Starship.”

Shana Diez, a Starship engineer at SpaceX, perhaps summed up Tuesday’s results best on X: “It’s not been an easy year but we finally got the reentry data that’s so critical to Starship. It feels good to be back!”

Under pressure after setbacks, SpaceX’s huge rocket finally goes the distance Read More »

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Time is running out for SpaceX to make a splash with second-gen Starship

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SpaceX is gearing up for another Starship launch after three straight disappointing test flights.

SpaceX’s 10th Starship rocket awaits liftoff. Credit: Stephen Clark/Ars Technica

STARBASE, Texas—A beehive of aerospace technicians, construction workers, and spaceflight fans descended on South Texas this weekend in advance of the next test flight of SpaceX’s gigantic Starship rocket, the largest vehicle of its kind ever built.

Towering 404 feet (123.1 meters) tall, the rocket was supposed to lift off during a one-hour launch window beginning at 6: 30 pm CDT (7: 30 pm EDT; 23: 30 UTC) Sunday. But SpaceX called off the launch attempt about an hour before liftoff to investigate a ground system issue at Starbase, located a few miles north of the US-Mexico border.

SpaceX didn’t immediately confirm when it might try again to launch Starship, but it could happen as soon as Monday evening at the same time.

It will take about 66 minutes for the rocket to travel from the launch pad in Texas to a splashdown zone in the Indian Ocean northwest of Australia. You can watch the test flight live on SpaceX’s official website. We’ve also embedded a livestream from Spaceflight Now and LabPadre below.

This will be the 10th full-scale test flight of Starship and its Super Heavy booster stage. It’s the fourth flight of an upgraded version of Starship conceived as a stepping stone to a more reliable, heavier-duty version of the rocket designed to carry up to 150 metric tons, or some 330,000 pounds, of cargo to pretty much anywhere in the inner part of our Solar System.

But this iteration of Starship, known as Block 2 or Version 2, has been anything but reliable. After reeling off a series of increasingly successful flights last year with the first-generation Starship and Super Heavy booster, SpaceX has encountered repeated setbacks since debuting Starship Version 2 in January.

Now, there are just two Starship Version 2s left to fly, including the vehicle poised for launch this week. Then, SpaceX will move on to Version 3, the design intended to go all the way to low-Earth orbit, where it can be refueled for longer expeditions into deep space.

A closer look at the top of SpaceX’s Starship rocket, tail number Ship 37, showing some of the different configurations of heat shield tiles SpaceX wants to test on this flight. Credit: Stephen Clark/Ars Technica

Starship’s promised cargo capacity is unparalleled in the history of rocketry. The privately developed rocket’s enormous size, coupled with SpaceX’s plan to make it fully reusable, could enable cargo and human missions to the Moon and Mars. SpaceX’s most conspicuous contract for Starship is with NASA, which plans to use a version of the ship as a human-rated Moon lander for the agency’s Artemis program. With this contract, Starship is central to the US government’s plans to try to beat China back to the Moon.

Closer to home, SpaceX intends to use Starship to haul massive loads of more powerful Starlink Internet satellites into low-Earth orbit. The US military is interested in using Starship for a range of national security missions, some of which could scarcely be imagined just a few years ago. SpaceX wants its factory to churn out a Starship rocket every day, approximately the same rate Boeing builds its workhorse 737 passenger jets.

Starship, of course, is immeasurably more complex than an airliner, and it sees temperature extremes, aerodynamic loads, and vibrations that would destroy a commercial airplane.

For any of this to become reality, SpaceX needs to begin ticking off a lengthy to-do list of technical milestones. The interim objectives include things like catching and reusing Starships and in-orbit ship-to-ship refueling, with a final goal of long-duration spaceflight to reach the Moon and stay there for weeks, months, or years. For a time late last year, it appeared as if SpaceX might be on track to reach at least the first two of these milestones by now.

The 404-foot-tall (123-meter) Starship rocket and Super Heavy booster stand on SpaceX’s launch pad. In the foreground, there are empty loading docks where tanker trucks deliver propellants and other gases to the launch site. Credit: Stephen Clark/Ars Technica

Instead, SpaceX’s schedule for catching and reusing Starships, and refueling ships in orbit, has slipped well into next year. A Moon landing is probably at least several years away. And a touchdown on Mars? Maybe in the 2030s. Before Starship can sniff those milestones, engineers must get the rocket to survive from liftoff through splashdown. This would confirm that recent changes made to the ship’s heat shield work as expected.

Three test flights attempting to do just this ended prematurely in January, March, and May. These failures prevented SpaceX from gathering data on several different tile designs, including insulators made of ceramic and metallic materials, and a tile with “active cooling” to fortify the craft as it reenters the atmosphere.

The heat shield is supposed to protect the rocket’s stainless steel skin from temperatures reaching 2,600° Fahrenheit (1,430° Celsius). During last year’s test flights, it worked well enough for Starship to guide itself to an on-target controlled splashdown in the Indian Ocean, halfway around the world from SpaceX’s launch site in Starbase, Texas.

But the ship lost some of its tiles during each flight last year, causing damage to the ship’s underlying structure. While this wasn’t bad enough to prevent the vehicle from reaching the ocean intact, it would cause difficulties in refurbishing the rocket for another flight. Eventually, SpaceX wants to catch Starships returning from space with giant robotic arms back at the launch pad. The vision, according to SpaceX founder and CEO Elon Musk, is to recover the ship, quickly mount it on another booster, refuel it, and launch it again.

If SpaceX can accomplish this, the ship must return from space with its heat shield in pristine condition. The evidence from last year’s test flights showed engineers had a long way to go for that to happen.

Visitors survey the landscape at Starbase, Texas, where industry and nature collide. Credit: Stephen Clark/Ars Technica

The Starship setbacks this year have been caused by problems in the ship’s propulsion and fuel systems. Another Starship exploded on a test stand in June at SpaceX’s sprawling rocket development facility in South Texas. SpaceX engineers identified different causes for each of the failures. You can read about them in our previous story.

Apart from testing the heat shield, the goals for this week’s Starship flight include testing an engine-out capability on the Super Heavy booster. Engineers will intentionally disable one of the booster’s Raptor engines used to slow down for landing, and instead use another Raptor engine from the rocket’s middle ring. At liftoff, 33 methane-fueled Raptor engines will power the Super Heavy booster off the pad.

SpaceX won’t try to catch the booster back at the launch pad this time, as it did on three occasions late last year and earlier this year. The booster catches have been one of the bright spots for the Starship program as progress on the rocket’s upper stage floundered. SpaceX reused a previously flown Super Heavy booster for the first time on the most recent Starship launch in May.

The booster landing experiment on this week’s flight will happen a few minutes after launch over the Gulf of Mexico east of the Texas coastline. Meanwhile, six Raptor engines will fire until approximately T+plus 9 minutes to accelerate the ship, or upper stage, into space.

The ship is programmed to release eight Starlink satellite simulators from its payload bay in a test of the craft’s payload deployment mechanism. That will be followed by a brief restart of one of the ship’s Raptor engines to adjust its trajectory for reentry, set to begin around 47 minutes into the mission.

If Starship makes it that far, that will be when engineers finally get a taste of the heat shield data they were hungry for at the start of the year.

This story was updated at 8: 30 pm EDT after SpaceX scrubbed Sunday’s launch attempt.

Photo of Stephen Clark

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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