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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

 

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 says SpaceX would not exist if this crucial early launch failed

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Credit: SpaceX

Elon Musk recently restated a fact that still defines SpaceX’s origin story: if Falcon 1’s fourth launch had failed, the company would not exist. The comment answered a reminder that after three consecutive losses, SpaceX had money for only one more attempt.

On X, Peter Diamandis said that the present-day acknowledgement of SpaceX’s success does not discount the rough start the company had. “Almost nobody remembers that Elon’s first rocket failed three times, and there was money for exactly only one more attempt.”

Musk said, “If the 4th launch had failed, SpaceX would not exist.”

In late 2008, the firm was nearly out of cash. Another failure would have ended payroll, closed the Hawthorne factory, and left the Falcon 9 and Dragon programs as unfinished drawings.

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The first flight lifted off from Omelek Island on 24 March 2006. Thirty-three seconds later, a corroded aluminum fitting on a fuel line leaked. Kerosene ignited around the Merlin engine, control was lost, and the vehicle came apart. The small DARPA payload, FalconSAT-2, survived the short flight only to land on a storage shed near the pad. Investigators later traced the fitting to a materials mix-up that should never have reached the rocket.

Flight 2, on 21 March 2007, looked far better at first. The first stage burned cleanly and handed off to the Kestrel-powered upper stage. The vehicle crossed 100 kilometers and reached a peak of about 289 kilometers. Then propellant slosh in the second-stage tank started a circular coning motion that grew until the engine shut down. Telemetry faded as the stage tumbled, and SpaceX had reached space but not orbit. Over the next year, the team redesigned everything from the ground up, including tanks, baffles, and the new regeneratively cooled Merlin 1C.

That engine flew on Flight 3 on 2 August 2008. The first stage performed almost perfectly and reached 217 kilometers. After main-engine cutoff, leftover fuel in the cooling channels produced a faint residual thrust, roughly 10 pounds per square inch of chamber pressure. On a Texas test stand, the effect was invisible beneath ambient air pressure. In vacuum it was enough to push the spent first stage back into the second stage after separation. The stages collided, the upper stage spun, and the mission was lost. Musk later said a slightly longer delay before staging would have saved the flight.

Six weeks later, the team assembled Flight 4 from remaining parts and flew it on 28 September 2008 at 23:15 UTC. The payload was Ratsat, a 165-kilogram aluminum mass simulator built in-house. Staging was delayed so residual thrust could decay. The Kestrel ignited, the fairing split away, and nine and a half minutes after liftoff the vehicle was in orbit. After a coast, the second stage restarted, settling into a 621-by-643-kilometer path at 9.35 degrees inclination. Falcon 1 became the first privately developed liquid-fueled rocket to reach Earth orbit. Musk called the insertion “middle of the bull’s-eye.”

SpaceX restores a Falcon 1 rocket for 10th anniversary of first launch success

That success unlocked NASA’s Commercial Resupply Services award later that year. Without it, there would have been no Falcon 9, no reusable first stages, and no Dragon cargo or crew flights to the International Space Station. Launch prices would have remained far higher. Starlink’s constellation would not exist; broadband from low Earth orbit would still be a paper concept.

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Ride-share markets, high launch cadence, and the current pace of lunar and Mars hardware would be years behind. Communications, Earth observation, and the cost of putting anything into space would look more like the 2000s than the 2020s.

One extra second of residual thrust in August 2008 would have written a different decade.

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Tesla surges Robotaxi fleet ahead of Cybercab launch event

Tesla’s unsupervised robotaxi fleet quietly grew sevenfold in three weeks just before Cybercab Day arrives.

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Tesla’s unsupervised Robotaxi fleet has grown far faster than the public numbers suggested, and the timing lines up with the company’s biggest autonomy showcase yet. According to data compiled by the crowdsourced Robotaxi Tracker, Tesla now has nearly 200 vehicles operating without a safety monitor across Austin, Dallas and Houston, yielding a roughly 7X increase in about three weeks.

The jump lands four days before this week’s Tesla Cybercab launch event in Austin, where the company plans to show off its purpose-built, two-seat robotaxi with no steering wheel or pedals in a live commercial setting for the first time. Stick with us on X and Facebook for live reporting from the event.

The strategic logic is straightforward. Tesla has spent the past year scaling Robotaxi in small, deliberate steps, first widening geofences, then extending operating hours, then quietly growing fleet size, usually with little advance notice. Ashok Elluswamy told investors on the Q2 earnings call that the program had logged more than 380,000 unsupervised miles with zero notable incidents, a safety record the company has leaned on to justify moving slowly. Critics have used the flip side of that caution, a fleet that appeared stuck around two dozen vehicles for months, as evidence that Tesla’s driverless ambitions were outrunning its actual deployment.

A fleet quietly scaling to nearly 200 vehicles right before Cybercab Day undercuts that argument without Tesla having to say anything about it directly. It also sets up the event to do double duty. Rather than simply introducing new hardware, Tesla can point to an operating base of unsupervised Model Ys already running at meaningful scale, then argue the Cybercab, which uses the same underlying Full Self-Driving stack according to earlier coverage of the fleet’s software upgrades, is a natural next steps. Tesla has separately been registering the two-seat Cybercabs with Texas regulators this week, with the count climbing from seven to 45 in a matter of days.

The two ramps, one in software-driven Model Y deployment and one in physical Cybercab registrations, are happening in parallel rather than in sequence. That suggests Tesla wants Thursday’s event to land as proof that the robotaxi business is already running at scale, not just a reveal of a new vehicle shape. Whether the unsupervised numbers hold up once Cybercabs start mixing into the same fleet is the detail worth watching once the event wraps.

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Cybertruck

Tesla Cybertruck windshield protection just got cheaper

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Credit: Tesla

Tesla is lowering the monthly price of its Cybertruck Windshield Protection Plan from $35 to $25. The new rate will apply to the first payment on or after October 1, 2026. Tesla has told subscribers that all other benefits stay the same.

The plan covers unlimited repairs for chips and minor cracks on the front windshield. It also includes one full replacement every 12 months at no extra charge. Additional replacements in the same year carry a $100 deductible. Service is performed with Tesla glass and camera calibration, which matters because Autopilot and Full Self-Driving rely on those lenses behind the windshield.

There is no long-term contract. Coverage applies only to the front glass and does not include collision, vandalism, or weather damage.

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The Cybertruck’s large, complex windshield has been more expensive to replace than glass on Tesla’s cars, which is why the pickup started at a higher subscription price. The $10 monthly cut reduces the annual cost from $420 to $300. Tesla has not publicly explained the change. The timing coincides with a year of claims data after the plan was extended to the Cybertruck.

Tesla sells several related protection products as monthly subscriptions through the Tesla app. The Windshield Protection Plan is also offered on other models. Model 3 and Model Y currently cost $16 a month. Those passenger-car rates are unchanged in the latest Cybertruck notice.

The Wheel and Tire Protection Plan covers road-hazard damage such as potholes, nails, and debris. Repairs are unlimited. Each wheel or tire replacement appointment has a $25 deductible. Pricing varies by model and whether the vehicle is a Performance version. Tesla is raising some of those rates on the same October 1 date.

Reported examples include Model 3 Performance moving from $16 to $24 and Model Y Performance from $20 to $24. Cybertruck wheel-and-tire coverage has been listed at $20 a month for the standard configuration.

A separate Luxe Package bundles four years of windshield coverage, wheel-and-tire coverage, and recommended maintenance on certain new Model S, Model X, and Cyberbeast orders, although the Model S and X are now defunct.

Tesla also offers an Extended Service Agreement after the basic vehicle warranty ends. That product covers many Tesla-manufactured parts rather than glass or tires. Together, the plans give owners a menu of targeted, cancel-anytime coverage instead of relying only on auto insurance.

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