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Falcon 9 B1047 seen aboard SpaceX drone ship Of Course I Still Love You. (SpaceX) Falcon 9 B1047 seen aboard SpaceX drone ship Of Course I Still Love You. (SpaceX)

SpaceX

SpaceX’s first dedicated Starlink launch announced as mass production begins

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SpaceX has announced a launch target of May 2019 for the first batch of operational Starlink satellites in a sign that the proposed internet satellite constellation has reached a major milestone, effectively transitioning from pure research and development to serious manufacturing.

R&D will continue as SpaceX Starlink engineers work to implement the true final design of the first several hundred or thousand spacecraft, but a significant amount of the team’s work will now be centered on producing as many Starlink satellites as possible, as quickly as possible. With anywhere from 4400 to nearly 12,000 satellites needed to complete the three major proposed phases of Starlink, SpaceX will have to build and launch a minimum of ~2200 satellites in the next five years, averaging 37 high-performance, low-cost spacecraft built and launched every month for the next 60 months.

A shift in the Stars

Despite the major challenges ahead of SpaceX, things seem to be going quite smoothly with the current mix of manufacturing and development. As previously reported on Teslarati, SpaceX CEO Elon Musk forced the Starlink group through a painful reorganization in the summer of 2018, challenging the remaining leaders and their team to launch the first batch of operational Starlink satellites no later than June 2019. As a consequence, a sort of compromise had to be reached where one additional group of quasi-prototype satellites would be launched before settling on a truly final design for serious mass-production.

According to SpaceX filings with the FCC, the first group of operational satellites – potentially anywhere from 75 to 1000 or more – will rely on just one band (“Ku”) for communications instead of the nominal two (“Ku” and “Ka”), a change that SpaceX says will significantly simplify the first spacecraft. By simplifying them, SpaceX believes it can expedite Starlink’s initial deployment without losing a great deal of performance or interfering with constellations from competitors like OneWeb.

OneWeb’s preliminary satellite production facility. (OneWeb)
SpaceX’s own Starlink deployment mechanism may look quite similar to this OneWeb-inspired render from Arianespace. (Arianespace)

Somewhere along the line, SpaceX would iteratively improve each subsequent ‘generation’ of Starlink satellites until they reached the nominal performance characteristics outlined in the company’s original constellation application. Knowing SpaceX, improvements would continue for as long as lessons continued to be learned from operating hundreds and eventually thousands of orbital spacecraft.

As one concrete example, recent SpaceX FCC documents stated that the first 75 Starlink spacecraft would feature a less-optimized reentry design, meaning that a select few components will not entirely burn up during reentry, creating debris that poses a slight added risk in the eyes of regulatory bodies like the FCC. After those first 75 spacecraft are built and launched, SpaceX will introduce upgrades – already planned and designed – that will reduce the surviving reentry debris (and thus their risk to humans below) to zero.

While the FCC has yet to grant SpaceX’s requested modifications, the other major goal is to reduce the operating orbit of the first phase of 1584 satellites to 550 km (340 mi), a change that SpaceX says will drastically reduce the potential lifespan of any orbital debris in the unlikely event of their creation. A lower altitude also places a major cushion between SpaceX’s first ~1500 satellites and the orbits of several other planned constellations, including OneWeb and Telesat.

Hello, Production Hell, my old friend

Meanwhile, SpaceX’s Starlink program has begun the often painful steps of transitioning from a venture primarily focused on research and development to one focused mainly on building production lines and supply chains and manufacturing hardware. SpaceX’s Starlink facilities are currently housed in three nearby buildings located in Redmond, Washington, likely offering approximately 150,000 square feet (14,000 m^2) for a mix of office, development, and production spaces. At least one of the three non-office buildings could potentially become dedicated to production while one building – approximately 40,000 ft^2 (~3500 m^2) – has already been completely transformed into a prototype of a Starlink satellite production line, supporting manufacturing for first several dozen quasi-prototype spacecraft. For reference, OneWeb’s dedicated satellite factory will feature around 100,000 square feet of space dedicated primarily to production, while the constellation’s satellites will be roughly half as large as SpaceX’s proposed Starlink satellites (~400 kg, 880 lb).

Mass-producing spacecraft at the scale needed to build even half of those needed for the first phase of ~4400 Starlink satellites will be a feat unprecedented in the history of the space industry. Barring FCC exemptions (possible but unlikely), SpaceX needs to launch ~2200 Starlink satellites between now and April 2024. To complete the first phase, the final number of satellites rises to ~4400. Adding on a proposed constellation of very low Earth orbit (VLEO) Starlink satellites, that number rises once more to a bit less than 12,000. Meanwhile, the cost of the satellites needs to be kept as low as possible while their performance is maximized. To put it in automotive terms, SpaceX needs to find a way to do the satellite equivalent of going from building Tesla’s original Roadster to the 2020 Roadster in just a handful of iterative generations and a few years.

One of the first two prototype Starlink satellites separates from Falcon 9’s upper stage, February 2018. (SpaceX)

Perhaps SpaceX will be able to garner invaluable insight from the lessons its sister company learned during Model 3’s torturous “production hell”, in which the car company had to grow its production volume by almost a magnitude as quickly as possible. Ironically, it may even be the case that SpaceX has the easier task relative to Tesla.

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Eric Ralph is Teslarati's senior spaceflight reporter and has been covering the industry in some capacity for almost half a decade, largely spurred in 2016 by a trip to Mexico to watch Elon Musk reveal SpaceX's plans for Mars in person. Aside from spreading interest and excitement about spaceflight far and wide, his primary goal is to cover humanity's ongoing efforts to expand beyond Earth to the Moon, Mars, and elsewhere.

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Elon Musk

Elon Musk reveals when SpaceX will perform first-ever Starship catch

“Starship catch is probably flight 13 to 15, depending on how well V3 flights go,” Musk said.

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Credit: SpaceX

Elon Musk revealed when SpaceX would perform the first-ever catch attempt of Starship, its massive rocket that will one day take life to other planets.

On Tuesday, Starship aced its tenth test flight as SpaceX was able to complete each of its mission objectives, including a splashdown of the Super Heavy Booster in the Gulf, the deployment of eight Starlink simulators, and another splashdown of the ship in the Indian Ocean.

It was the first launch that featured a payload deployment:

SpaceX Starship Flight 10 was so successful, it’s breaking the anti-Musk narrative

SpaceX was transparent that it would not attempt to catch the Super Heavy Booster, something it has done on three previous occasions: Flight 5 on October 13, 2024, Flight 7 on January 16, and Flight 8 on March 6.

This time, it was not attempting to do so. However, there are bigger plans for the future, and Musk detailed them in a recent post on X, where he discussed SpaceX’s plans to catch Starship, which would be a monumental accomplishment.

Musk said the most likely opportunities for SpaceX to catch Starship itself would be Flight 13, Flight 14, and Flight 15, but it depends on “how well the V3 flights go.”

The Starship launched with Flight 10 was a V2, which is the same size as the subsequent V3 rocket but has a smaller payload-to-orbit rating and is less powerful in terms of initial thrust and booster thrust. Musk said there is only one more V2 rocket left to launch.

V3 will be the version flown through 2026, as V4, which will be the most capable Starship build SpaceX manufactures, is likely to be the first company ship to carry humans to space.

Musk said that SpaceX planned to “hopefully” attempt a catch of Starship in 2025. However, it appears that this will likely be pushed back to 2026 due to timing.

SpaceX will take Starship catch one step further very soon, Elon Musk confirms

SpaceX would need to launch the 11th and 12th test flights by the end of the year in order to get to Musk’s expected first catch attempt of Flight 13. It’s not unheard of, but the company will need to accelerate its launch rate as it has only had three test flights this year.

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Elon Musk

SpaceX Starship Flight 10 was so successful, it’s breaking the anti-Musk narrative

That’s all the proof one could need about the undeniable success of Starship Flight 10.

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Credit: Elon Musk/X

Starship Flight 10 was a huge success for SpaceX. When both the Super Heavy booster and the Starship Upper Stage successfully landed on their designated splashdown zones, the space community was celebrating.

The largest and most powerful rocket in the world had successfully completed its tenth test flight. And this time around, there were no rapid unscheduled disassemblies during the mission.

As per SpaceX in a statement following Flight 10, “every major objective was met, providing critical data to inform designs of the next generation Starship and Super Heavy.” The private space enterprise also stated that Flight 10 provided valuable data by stressing the limits of Starship’s capabilities.

With all of Flight 10’s mission objectives met, one would think that it would be pretty easy to cover the story of Starship’s successful tenth test flight. But that’s where one would be wrong, because Elon Musk companies, whether it be Tesla or SpaceX or xAI, tend to attract negative slant from mainstream media outlets.

This was in full force with Starship Flight 10’s coverage. Take the BBC’s Facebook post about the fight test, which read “Elon Musk’s giant rocket, earmarked for use in a 2027 mission to the Moon, has had multiple catastrophic failures in previous launches.” CNN was more direct with its slant, writing “SpaceX’s troubled Starship prototype pulls off successful flight after months of explosive mishaps” on its headline. 

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While some media outlets evidently adopted a negative slant towards Starship’s Flight 10 results, several other media sources actually published surprisingly positive articles about the successful test flight. The most notable of which is arguably the New York Times, which featured a headline that read “SpaceX’s Giant Mars Rocket Completes Nearly Flawless Test Flight.” Fox News also ran with a notably positive headline that read “SpaceX succeeds at third Starship test flight attempt after multiple scrubs.”

Having covered Elon Musk-related companies for the better part of a decade now, I have learned that mainstream coverage of any of his companies tends to be sprinkled with varying degrees of negative slant. The reasons behind this may never be fully explained, but it is just the way things are. This is why, when milestones such as Starship’s Flight 10 actually happen and mainstream media coverage becomes somewhat objective, I can’t help but be amazed. 

After all, it takes one heck of a company led by one heck of a leader to force objectivity on an entity that has proven subjective over the years. And that, if any, is all the proof one could need about the undeniable success of Starship Flight 10.

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SpaceX aces Starship test flight 10 with successful payload deployment

The mission began at 6:30 p.m. local time in Starbase, Texas, when the launch of Starship initiated. After about eight minutes, stage separation was completed, and the Super Heavy Booster headed back down to Earth for a planned splashdown in the Indian Ocean:

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Credit: SpaceX

SpaceX aced its tenth Starship test flight on Tuesday night after multiple delays pushed the mission back to this evening. Originally scheduled for Sunday night, SpaceX had two delays push the flight back to Tuesday, which ultimately provided ideal conditions for a launch attempt.

The tenth test flight of Starship had several objectives, including a successful splashdown of the booster in the Gulf of America, the deployment of eight Starlink simulation modules from the PEZ dispenser, and a splashdown of the ship in the Indian Ocean.

SpaceX Starship Flight 10: What to expect

SpaceX successfully achieved all three of these objectives, making it one of the most successful test flights in the Starship program. There was no attempt to catch the booster this evening, as the company had been transparent about it ahead of the launch.

The mission began at 6:30 p.m. local time in Starbase, Texas, when the launch of Starship initiated. After about eight minutes, stage separation was completed, and the Super Heavy Booster headed back down to Earth for a planned splashdown in the Indian Ocean:

Starship was then the main focus of the rest of the broadcast as it completed its ascent burn and coasted through space, providing viewers with spectacular views as the mission headed toward new territory, including the deployment of Starlink simulators. This would be the first time SpaceX would attempt a payload deployment.

The deployment works like a PEZ dispenser, as the simulators were stacked on top of one another and would exit through a small slit one at a time.

This occurred roughly 20 minutes into the mission:

An hour and six minutes into the flight, Starship reached its final destination, which was the Indian Ocean. A successful splashdown would bring closure to Starship’s tenth test flight, marking the fifth time a test flight in the program’s history did not end with vehicle loss.

It was also the first of four test flights this year that will end with Starship being recovered.

SpaceX is expected to launch Starship again in approximately eight weeks, pending the collection of data and other key metrics from this flight.

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