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DeepSpace: Firefly’s Alpha rocket to get a massive upgrade with ion thruster boost stage ⚡ ?

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Eric Ralph · June 18th, 2019

Welcome to the latest edition of DeepSpace! Each week, Teslarati space reporter Eric Ralph hand-crafts this newsletter to give you a breakdown of what’s happening in the space industry and what you need to know. To receive this newsletter (and others) directly and join our member-only Slack group, give us a 3-month trial for just $5.


Although the company quietly teased the concept for the first time several months ago, Firefly has released a detailed update on its Orbital Transfer Vehicle (OTV), an ambitious spacecraft meant to complement its Alpha and Beta launch vehicles. If Firefly can deliver on the independent spacecraft’s technical promises, the combination of Alpha (~$15M) and OTV could help usher in a new era of small, high-performance satellites launched on small, high-performance rockets.

In fact, Rocket Lab – currently the world’s only truly commercial smallsat launch provider – has already demonstrated the power of this new paradigm, albeit on a smaller scale. After just one failed attempt, the first successful orbital launch of the company’s Electron rocket also marked the surprise debut of a tiny third stage used to circularize the payload’s orbit. After five successful uses in orbit, Rocket Lab has taken its third stage a step further, adding redundant avionics, solar arrays, and more to effectively create an independent spacecraft/satellite bus called Photon. By all appearances, Firefly’s OTV is much larger than Photon but is functionally quite similar. By taking advantage of Alpha’s significant performance benefits compared to Electron, Firefly has designed a third stage/spacecraft capable of delivering hundreds of kilograms to geostationary orbit, the Moon, and (perhaps) beyond.

Changing the delta V game

  • Generally speaking, OTV is quite small. According to Firefly’s Payload User’s Guide, the spacecraft will weigh just 130 kg (285 lb) dry and will carry perhaps 30-70 kg of xenon fuel for its electric ion thrusters. This is a critical differentiator relative to Rocket Lab’s Photon and kick stage, which rely on the inefficient (but simple and reliable) Curie chemical rocket engine.
    • According to Firefly, Alpha is designed to launch a max of 1000 kg (2200 lb) to a 200 km (125 mi) low Earth orbit (LEO). Given OTV’s ~200 kg wet mass, Alpha + OTV offer some incredible capabilities relative to the rocket’s size and design.
    • Powerful electric thrusters undeniably add a lot of complexity to any spacecraft that chooses to use them but that pain is often deemed worth it for the benefits they can offer. Most notably, ion propulsion is extremely efficient.
This graph demonstrates the potential performance benefits of Alpha + OTV relative to Alpha on its own. (Firefly)
  • Thanks to OTV’s efficient electric thrusters and light carbon composite structure, the potential benefits of Alpha + OTV are hard to believe for a rocket as (relatively) small as Alpha.
  • On its own, Alpha can only deliver a meaningful payload (~100 kg) to perhaps 4000 km (2500 mi). With OTV, Alpha can suddenly deliver ~600 kg to a circular geostationary orbit (~36,000 km, 22,300 mi) and upwards of 400-500 kg into orbit around the Moon.
    • For reference, despite weighing around 10% of Falcon 9, Alpha and OTV would offer perhaps 10-15% the performance of Falcon 9 to trans lunar injection (TLI). This utterly defies the general rule of thumb that as a rocket gets significantly smaller, its performance (particularly to higher-energy orbits) deteriorates disproportionately.
  • With OTV, Alpha – nominally a ~$15M launch vehicle relegated to LEO payloads – becomes an incredibly intriguing option for small geostationary communications satellites and small-scale public and private exploration of the Moon, near Earth asteroids, and maybe even Mars/Venus.
  • According to a senior Firefly investor and board member, Firefly hopes to have OTV ready for its orbital debut on Alpha’s third launch, tentatively scheduled no earlier than mid-2020.

Alpha readies for launch

  • Of course, OTV is a bird without wings without Firefly’s Alpha launch vehicle. Weighing 54,000 kg (120,000 lb) fully-fueled, Alpha is a two-stage rocket that will stand 1.8m (6ft) wide and 29m (95ft) tall. Powered by four Reaver engines, the first stage will produce ~740 kN (166,000 lbf), approximately 85% of one of Falcon 9’s nine Merlin 1D engines.
  • Firefly is working relentlessly towards an ambitious December 2019 Alpha launch debut, a target that will probably slip into early 2020 due to the inherent complexity of the task at hand. Critically, though, Firefly has made a huge amount of progress towards that goal.
    • Notably, Firefly’s second stage – powered by one vacuum-optimized Lightning engine – has already been qualified for launch with full-duration static fires at the company’s Texas facilities. Firefly is in the midst of preparing for an identical series of qualification tests for its more powerful first stage, shown above in the form of one Reaver engine attached to an Alpha S1 thrust structure.
    • As early as July, a full set of four Reaver engines will be installed on the same thrust structure to perform static fire testing, much like SpaceX gradually added Merlin 1D engines during Falcon 9 development testing.
  • If all goes as planned, Firefly will have completed its first Alpha rocket – first stage, second stage, and payload fairing – by October or November 2019. Expect plenty of new photos and updates as Alpha nears its inaugural launch.
Thanks for being a Teslarati Reader! Become a member today to receive an issue of DeepSpace in your inbox each week!

– Eric

 

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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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Tesla CEO Elon Musk outlines expectations for Cybercab production

“…initial production is always very slow and follows an S-curve. The speed of production ramp is inversely proportionate to how many new parts and steps there are. For Cybercab and Optimus, almost everything is new, so the early production rate will be agonizingly slow, but eventually end up being insanely fast.”

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Credit: Tesla

Tesla CEO Elon Musk outlined expectations for Cybercab production as the vehicle is officially set to start rolling off manufacturing lines at the company’s Giga Texas factory in less than 100 days.

Cybercab is specifically designed and catered to Tesla’s self-driving platform and Robotaxi ride-hailing service. The company has been pushing hard to meet its self-set expectations for rolling out an effective self-driving suite, and with the Cybercab coming in under 100 days, it now needs to push for Unsupervised Self-Driving in the same time frame.

Tesla CEO Elon Musk confirms Robotaxi is set to go unsupervised

This is especially pertinent because the Cybercab is expected to be built without a steering wheel or pedals, and although some executives have said they would build the car with those things if it were necessary.

However, Musk has maintained that the Cybercab will not have either of those things: it will have two seats and a screen, and that’s it.

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With production scheduled for less than 100 days, Musk broke down what people should expect from the initial manufacturing phases, being cautiously optimistic about what the early stages will likely entail:

“…initial production is always very slow and follows an S-curve. The speed of production ramp is inversely proportionate to how many new parts and steps there are. For Cybercab and Optimus, almost everything is new, so the early production rate will be agonizingly slow, but eventually end up being insanely fast.”

Musk knows better than most about the challenges of ramping up production of vehicles. With the Model 3, Musk routinely refers to it as “production hell.” The Cybertruck, because of its polarizing design and stainless steel exterior, also presented challenges to Tesla.

The Cybercab definitely presents an easier production process for Tesla, and the company plans to build millions of units per year.

Musk said back in October 2024:

“We’re aiming for at least 2 million units a year of Cybercab. That will be in more than one factory, but I think it’s at least 2 million units a year, maybe 4 million ultimately.”

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When April comes, we will find out exactly how things will move forward with Cybercab production.

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Tesla reveals awesome Model 3 and Model Y incentive, but it’s ending soon

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Credit: Tesla Europe & Middle East/X

Tesla has revealed an awesome Model 3 and Model Y incentive to help consumers make the jump to one of its affordable mass-market vehicles, but it’s ending soon.

Tesla is offering one free upgrade on eligible inventory of the Model 3 and Model Y until February 2.

This would help buyers receive the most expensive paid option on the vehicle at no additional cost, meaning white interior or a more premium paint option will be free of charge if you take delivery on or before February 2.

Tesla states on its website for the offer:

“Only for limited inventory while supplies last. Price displayed on inventory listings already deducts the cost of the free option.”

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This latest incentive is just another advantage Tesla has by selling its vehicles directly and not using some sort of dealership model that relies on approvals from higher-ups. It is important to note that these programs are offered to help stimulate demand and push vehicles into customers’ hands.

It is not the only incentive Tesla is currently offering, either. In fact, there is a much larger incentive program that Tesla is working on, and it has to do with Full Self-Driving transfers, which could result in even more sales for the company through Q1.

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Tesla is ending its FSD Transfer program on March 31, as it plans to transition to a Subscription-only basis with the self-driving suite for anyone who has not already purchased it outright.

This could help drive some on-the-fence buyers to new vehicles, but it remains to be seen. Given the timing of the program’s demise, it appears Tesla is hoping to use it to add additional sales and bolster a strong Q1 2026.

Interior and exterior paint colors can add up to $2,000 if you choose the most premium Ultra Red body color, or an additional $1,000 for the Black and White interior option. The discount, while small, could help get someone their preferred design configuration, instead of settling for something that is not quite what they want.

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Tesla Full Self-Driving gets outrageous insurance offer with insanely cheap rates

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Credit: Ashok Elluswamy/X

Tesla Full Self-Driving is getting an outrageous insurance offer with insanely cheap rates that will slash the cost of coverage by 50 percent.

Lemonade, a digital insurance company, has launched its first-of-a-kind product known as Lemonade Autonomous Car Insurance, and it is starting with an exclusive offer to FSD. The new offer will cut rates for FSD-engaged driving by “approximately 50 percent,” highlighting the data that shows a significantly safer driving environment when the suite is activated and engaged.

The company also said it plans to introduce even cheaper rates as Tesla continues to release more advanced FSD versions through software updates. Tesla has been releasing new FSD versions every few weeks, highlighting vast improvements for those who have the latest AI4 chip.

The announcement comes just a few months afterLemonade Co-Founder and President Shai Wininger said that he wanted to insure FSD vehicles for “almost free.” He said that Tesla’s API complemented Lemonade’s AI-based platform because it provides “richer and more accurate driving behavior data than traditional UBI devices.”

Tesla Full Self-Driving gets an offer to be insured for ‘almost free’

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In mid-December, Lemonade then offered Tesla owners in California, Oregon, and Arizona the opportunity to connect their vehicles directly to the company’s app, which would provide a direct connection and would require a separate telematics device, which is required with other insurance providers who offer rates based on driving behaviors.

This latest development between Lemonade and Tesla is something that Wininger believes will be different because of the advanced nature of FSD:

“Traditional insurers treat a Tesla like any other car, and AI like any other driver. But a car that sees 360 degrees, never gets drowsy, and reacts in milliseconds can’t be compared to a human.”

He went on to say that the existing pay-per-mile product has given the company something that no traditional insurer has been able to offer. This comes through Lemonade’s “unique tech stack designed to collect massive amounts of real driving data for precise, dynamic pricing.”

The reputation FSD has gathered over the past few years is really impressive. Wininger backed this with some more compliments:

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“Teslas driven with FSD are involved in far fewer accidents. By connecting to the Tesla onboard computer, our models are able to ingest incredibly nuanced sensor data that lets us price our insurance with higher precision than ever before.”

The product will begin its official rollout in Arizona on January 26. Oregon will get it a month later.

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