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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 plans to adjust heavily scrutinized car part with simple engineering

“We’ll have a really good solution for that. I’m not worried about it.”

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Tesla Model S self-presenting door handle
Tesla Model S self-presenting door handle (Credit: TesBros)

Tesla is going to adjust one heavily scrutinized part of its vehicles after recent government agencies have launched probes into an issue stemming from complaints from owners.

Over the past few days, we have reported on the issues with Tesla’s door handle systems from both the Chinese and American governments.

In China, it dealt with the Model S, while the United States’ National Highway Traffic Safety Administration (NHTSA) reported nine complaints from owners experiencing issues with 2021 Model Ys, as some said they had trouble entering their car after the 12V battery was low on power.

Bloomberg, in an interview with Tesla Chief Designer Franz von Holzhausen, asked whether the company planned to adjust the door handle design to alleviate any concerns that regulatory agencies might have.

Regarding the interior latch concerns in the United States:

  • Von Holzhausen said that, while a mechanical door release resolves this problem, Tesla plans to “combine the two” to help reduce stress in what he called “panic situations.”
  • He also added that “it’s in the cars now…The idea of combining the electronic and the manual one together in one button, I think, makes a lot of sense.” Franz said the muscle memory of reaching for the same button will be advantageous for children and anyone who is in an emergency.

Regarding the exterior door handle concerns in China:

  • Von Holzhausen said Tesla is reviewing the details of the regulation and confirmed, “We’ll have a really good solution for that. I’m not worried about it.”

The new Model Y already has emergency mechanical door release latches in the back, but combining them in future vehicles seems to be an ideal solution for other vehicles in Tesla’s lineup.

It will likely help Tesla avoid complaints from owners about not having an out in the event of a power outage or accident. It is a small engineering change that could be extremely valuable for future instances.

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Elon Musk calls out viral claim of 10,000 Tesla Optimus deal: “Fake”

For now at least, Tesla seems determined to focus on the development of Optimus V3.

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Credit: Tesla Optimus/X

Elon Musk has provided some clarification to recent reports suggesting that PharmAGRI, a US pharmaceutical and agricultural infrastructure company, is looking to deploy 10,000 Optimus robots for its operations.

Musk posted his clarification on social media platform X.

Alleged Optimus purchase

Recently, reports emerged stating that PharmAGRI Capital Partners will be tapping into Tesla’s humanoid robots for its operations. The firm claimed that it had executed a Letter of Intent with Tesla to deploy up to 10,000 Optimus Gen 3+ humanoid robots across its SuperPharm and CEA facilities. This should allow the company to automate its labor and ensure diversion control.

A comment from Lynn Stockwell, Chairwoman & CEO, suggested that the company really was partnering with Tesla. “With Tesla robotics powering our facilities and DEA-licensed infrastructure in place, we can scale with precision, meet federal sourcing mandates, and deliver therapies that are compliant, secure, and American-made,” she said. 

Elon Musk clariies

News of PharmAGRI’s Optimus claims quickly spread on social media, though some Tesla watchers argued that it seemed unlikely that the EV maker will commit two legions of Optimus robots to a rather unknown company this early. Some pointed out that Tesla typically commits to high-profile customers to test its early products, such as PepsiCo with the Tesla Semi. 

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Photos from PharmAGRI’s website depicting Tesla Optimus bots, as well as the rather basic look of the website itself, also brought more reservations to the company’s claims. Ultimately, Elon Musk weighed in on the matter, responding to a post about PharmAGRI’s Optimus-filled webpage. Musk was quick and direct, simply stating, “Fake.”

Elon Musk’s comments were quite unsurprising considering that Optimus is still very much in active development, and thus, it is quite unlikely that the company is already taking orders or even Letters of Intent from potential customers at this time. For now at least, Tesla seems determined to focus on the development of Optimus V3, which Musk has noted will be “sublime.”

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Elon Musk: Self-sustaining city on Mars is plausible in 25-30 years

Musk noted that true self-sufficiency requires Mars to develop “all the ingredients of civilization.”

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Credit: Elon Musk/X

Elon Musk has stated that a self-sustaining human settlement on Mars could be established in 25-30 years, provided launch capacity increases dramatically in the coming decades. 

Speaking at the All-In Summit, the SpaceX CEO said building a self-sufficient colony depends on exponential growth in “tonnage to Mars” with each launch window, highlighting Starship’s role as the company’s pathway to interplanetary initiatives.

Mars settlement goals

Musk noted that true self-sufficiency requires Mars to develop “all the ingredients of civilization,” from food production to microchip manufacturing. Starship Version 3 is expected to support the first uncrewed Mars test flights, while future iterations could reach 466 feet in height and deliver larger payloads critical for settlement. Ultimately, Musk stated that an aggressive timeline for a city on Mars could be as short as 30 years, as noted in a Space.com report.

“I think it can be done in 30 years, provided there’s an exponential increase in the tonnage to Mars with each successive Mars transfer window, which is every two years. Every two years, the planets align and you can transfer to Mars. 

“I think in roughly 15, but maybe as few as 10, but 10-15-ish Mars transfer windows. If you’re seeing exponential increases in the tonnage to Mars with each Mars transfer window, then it should be possible to make Mars self-sustaining in about call it roughly 25 years,” Musk said. 

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Starship’s role

Starship has flown in a fully stacked configuration ten times, most recently in August when it completed its first payload deployment in orbit. The next flight will close out the Version 2 program before transitioning to Starship Version 3, featuring Raptor 3 engines and a redesigned structure capable of lifting over 100 tons to orbit.

While SpaceX has demonstrated Super Heavy booster reuse, Ship reusability remains in development. Musk noted that the heat shield is still the biggest technical hurdle, as no orbital vehicle has yet achieved rapid, full reuse.

“For full reusability of the Ship, there’s still a lot of work that remains on the heat shield. No one’s ever made a fully reusable orbital heat shield. The shuttle heat shield had to go through nine months of repair after every flight,” he said. 

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