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DeepSpace: Rocket Lab ready for first commercial launch of 2019, an innovative DARPA spacecraft

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This is a free preview of DeepSpace, Teslarati’s new member-only weekly newsletter. Each week, I’ll be taking a deep-dive into the most exciting developments in commercial space, from satellites and rockets to everything in between.

If you’d like to receive this DeepSpace newsletter and all of our newsletters and membership benefits, you can become a member for as little as $3/month here.

Now approximately four months distant from the inaugural commercial launch of Rocket Lab’s Electron rocket, the company is ready – following many weeks of customer-side delays – to conduct its first launch of 2019, aiming to place an experimental DARPA-funded satellite into low Earth orbit (LEO). 

If all goes as planned with the launch and experimental spacecraft’s orbital operations, Defense Advanced Research Projects Agency (DARPA) hopes to use the mission to qualify a currently-untested technology that could ultimately enable the production of massive communications and sensing antennas that can fit on relatively tiny satellites. Known as R3D2 (ha…ha…), the mission also effectively serves as the latest operational debut of DARPA’s growing interest and involvement in spaceflight-related industries, nominally proving that the agency is capable of leaning on established companies and startups to rapidly design, build, and fly satellites. Barring any additional launch delays from DARPA’s preparations, Rocket Lab hopes to launch Electron around the end of this week – likely March 22-24 – to kick off what will hopefully be a busy and productive year for the newly operational launch provider. 

DARPA in Space

  • Originally targeted for sometime in the second half of February, the R3D2 mission – Electron’s fifth planned launch in 18 months – has suffered several weeks of delays due to issues faced by DARPA during satellite delivery and pre-launch preparations.
    • Aside from a general hint that the satellite arrived a few weeks later than planned and an official statement from Rocket Lab that “DARPA’s payload team is conducting final ground station configuration work over the coming days”, the process appears to be going rather smoothly. 
  • Weighing in at roughly 150 kg (330 lb), the R3D2 spacecraft – barring the quiet inclusion of co-passengers – will be the first launch of Electron dedicated to a single satellite. In fact, 150 kg is actually the maximum listed payload that Electron is capable of launching to a 500 km (310 mi) sun-synchronous orbit (SSO), providing a functional ‘ceiling’ for the ultimate destination of DARPA’s satellite.
    • R3D2’s primary purpose will be to extensively test a brand new antenna technology and thus prove (hopefully) that the in-space deployment mechanism and unique material composition function as designed. Likely no more than 1-2 feet (~50 cm) across, the definitively small satellite will attempt to deploy an antenna many times larger than itself. 
    • Made out of a material known as Kapton, the deployable antenna will reach a maximum diameter of 2.25 m (7.4 ft), fairly large even when compared with antennas used on satellites many dozens of times more massive. 

Rocket Lab’s Biggest year yet

  • Although the company is off to a relatively slow start, as many as eleven Electron missions – including R3D2 – are at least tentatively manifested for launches in 2019.
  • In November and December of 2018, Rocket Lab further demonstrated that it is more than capable of a respectable monthly launch cadence, particularly impressive for a rocket conducting its third and fourth missions ever. If Rocket Lab can more or less sustain that cadence after DARPA’s R3D2, the company could ultimately complete as many as 8-10 launches this year.
  • Ultimately, founder and CEO Peter Beck says that Rocket Lab and Electron will eventually target dozens of annual launches per year and a weekly launch cadence from an array of launch facilities.
    • Earlier this year, Rocket Lab officially announced that it had come to an agreement with the state of Virginia to build its second launch complex (LC-2) at Wallops Flight Facility (also known as the Mid-Atlantic Spaceport). If construction proceeds apace, the company’s first US-based Electron launch could occur before the end of 2019.
Rocket Lab’s Electron – built almost entirely out of carbon fiber composites – is an undeniably spectacular rocket, building heavily on New Zealand’s unique global expertise in high-performance composites, an offshoot of a very healthy sailing industry. (Rocket Lab)

  • DARPA’s goal with R3D2 – and its interest in space and small satellites in general – should ultimately benefit the entire spaceflight industry, potentially paving the way for the design and production of small satellites with technical capabilities that far outstretch their compact nature.
    • Reliable and affordable deployable structures are becoming a growing focus of a number of young and old spaceflight companies, ranging from heavyweights like SSL/Maxar to new startups like Oxford Space Systems. 
  • Unlike most modern defense and aerospace technology procurement, DARPA is also distinctly focused on streamlining the process of designing, building, and launching spacecraft. To do so, the agency plans to rely heavily on established commercial entities to optimize speed and affordability will still ultimately producing innovative space systems and pushing the state of the art forward.
  • Aside from closely involved projects like R3D2, DARPA – through a program called Blackjack – is also extremely interested in a number of LEO communications constellations proposed in the last few years by companies like SpaceX, OneWeb, and Telesat, and has already awarded a series of small contracts with several to begin the program’s earliest phases.

Mission Updates

  • Completed on March 8th, SpaceX’s near-flawless Crew Dragon launch, space station rendezvous, and recovery is likely the last of the company’s orbital launch activities for the month of March. 
  • The second launch of Falcon Heavy – the rocket’s commercial debut – is currently expected to occur as early as April 7th
  • After Falcon Heavy, SpaceX has at least one other launch – Cargo Dragon’s CRS-17 resupply mission – firmly scheduled for April (April 25th), as well as the more tenuous possibility of the first dedicated Starlink launch occurring as early as late April.

Photos of the Week: 

NASA posted a series of official photos documenting SpaceX’s Crew Dragon recovery process following the spacecraft’s first successful orbital reentry and splashdown. The photo below (top) offers one of the best (and most detailed) views ever made public of one of the heat shields of a SpaceX Dragon spacecraft, offering a glimpse of the wear the PICA-X material experiences after several minutes of extreme heating and buffeting. (c. NASA/Cory Huston)

Back on land, SpaceX’s South Texas entourage has continued to build the first full-scale Starship prototype – nicknamed Starhopper – in preparation for the vehicle’s inaugural static-fire and hop tests. According to official SpaceX statements, those tests could occur as early as this week, partially confirmed by the first installation of a Raptor engine (serial number 2) on a flight article of any kind.(c. NASASpaceflight – bocachicagal)

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 Semi catches fire in California: what we know

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Credit: KTVU

A Tesla Semi caught fire in Hayward, California, which caused both directions of traffic to shut down for hours before being completely reopened early on Wednesday, the California Highway Patrol said.

The fire occurred just after 5:30 local time in Hayward on Tuesday, as the Semi caught fire in the southbound lanes of I-880 before CHP officials made the decision to shut down both lanes of traffic due to potential risks from hazardous chemical smoke.

There were no injuries reported.

The cause of the fire is currently unknown, as neither Tesla nor the CHP have not determined a cause.

However, some images taken before the Semi was completely destroyed by the fire seem to indicate this might have been an older unit, as it appears to be one of the designs that Tesla shipped as part of its pilot program, before revising it and starting mass production just a month ago.

At the time of publication, CHP had not returned our request for a comment for additional details, including the Semi involved and any potential collaboration on an investigation between the CHP and Tesla. We will update this story when we hear back from them.

The southbound lanes were reopened at 3:30 a.m. on Wednesday, with the northbound lanes opening last night a few hours after the fire began. The CHP did state that the lithium batteries were “incredibly difficult to extinguish,” according to NBC Bay Area.

The truck’s driver said that the Semi caught fire, but he did not have an explanation.

An estimated 5,000 to 7,000 semi-truck and large commercial vehicle fires occur on U.S. roadways every year.

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Tesla’s ‘Emergency Drive Away’ function gets its first use in the real world

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Credit: Tesla

Tesla’s launch of the “Emergency Drive Away” function a few months back offered owners a safe option to evacuate an area if they were in reasonable danger. The function finally got its first use in the real world, but it appears it was by mistake.

A video shared by u/Joshalander in the r/TeslaLounge subreddit recorded the instance from his vehicle and said the incident took place in Austin this past weekend during the city’s F1 Race.

“Was charging around 6 AM this past Sunday in Austin before heading to the F1 race and heard a pop. Looked over and saw the new emergency drive-away feature in action. Genuinely felt bad for the dude when he got out and realized what happened, since he looked exhausted and only seemed to half-read the prompts.”

Emergency Drive Away unlatches the Supercharger connector from the vehicle, but still causes damage to both the car and the Supercharger. Tesla has said that it will cost up to $25,000 in repairs to have everything fixed back to normal.

Additionally, the company said that if it were not used in an emergency situation, the driver of the vehicle who activated the Emergency Drive Away feature would be responsible for all repair costs.

Tesla constitutes the following situations as reasonable justifications for activating the feature:

  • You face an immediate threat to your life or personal safety.
  • You must leave the area immediately.
  • Exiting the vehicle is unsafe.
  • Unplugging the charge connector would unreasonably delay your departure or expose you to a risk to your personal safety.

After using the feature, Tesla requires the driver to schedule Service so the car can be inspected.

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Tesla’s Cybercab battery design could make robotaxis even cheaper

Tesla built the Cybercab’s battery pack with spare room for a future switch to LFP.

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Tesla built the Cybercab’s battery pack with empty space inside it on purpose, and the reason points to a cheaper robotaxi down the road.

Robert Sumpf, Tesla’s director of mechanical design engineering for battery modules and packs, said the extra room beside and beneath the Cybercab’s modules was left there so the company can move to lithium iron phosphate cells later. “So, we protected this pack to go to an even lower energy dense chemistry as we scale and need to bring LFP into the platform,” Sumpf said in a Cybercab deep dive with Munro Live.

The Cybercab runs on Tesla’s own 4680 cells with a nickel chemistry today. LFP cells store less energy for their size, so a straight swap would cut range. The reserved space lets Tesla add more LFP cells to make up the difference. In return, Tesla would get cells that cost less, run cooler and survive more charge cycles. LFP became the most used EV battery chemistry in the world last year.

Not all of that room was planned for a chemistry change. Lars Moravy, Tesla’s Vice President of Vehicle Engineering, said part of it exists because “we didn’t need as many batteries as we thought we did.” Tesla told Sandy Munro in early 2025 that it was targeting a Cybercab pack under 50 kWh with close to 300 miles of range.

The pack also breaks from the structural design Tesla used in some Model Y and Cybertruck builds. Instead of potting hundreds of cells into one block, the Cybercab uses four separate, individually sealed modules, so a bad module can be replaced without scrapping the whole pack. Sumpf was blunt about the older approach, giving the Model Y structural battery “a grade D” because it was hard to build and nearly impossible to repair. He estimated a fully structural pack gains about 10% more cell volume, but said “the issue is the service cost.”

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That cost matters more for a car that rarely sits parked. Cybercab chief engineer Eric Earley said replacing an entire pack “before half a million miles is a killer on cost,” which is why remanufacturing and serviceability were built into the design from the start.

The same Munro Live tour produced Moravy’s admission that the Cybercab line at Giga Texas is now outpacing Robotaxi deployments, along with a look at the robotaxi’s unorthodox paint process. Tesla is aiming to deliver the first Cybercabs to outside customers by the end of 2026, though Elon Musk has said the vast majority will stay owned by Tesla and run as a transport service.

Sumpf did not give a date for an LFP version, name a cell supplier or say how a chemistry change would affect range. For now, the 4680 cars keep piling up: Texas DMV records from Tuesday list 544 Cybercabs authorized for Tesla’s Robotaxi fleet, more than the 507 Model Ys on the same roster for the first time.

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