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Rocket Lab’s first step towards SpaceX-style rocket reuse set for next Electron launch

A render of a Rocket Lab Electron first stage booster as it re-enters the Earth's atmosphere. (Rocket Lab)

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Just over a year ago, Rocket Lab announced intentions to recover the first-stage of its small Electron launch vehicle, potentially making it the second private company on Earth – after SpaceX – to attempt to recover and reuse an orbital-class rocket.

In a media call earlier this week, Rocket Lab founder and CEO, Peter Beck, revealed that the first recovery attempt has been expedited to mid-November and will occur following the next flight of Rocket Lab’s Electron rocket.

A glimpse of the Electron booster of the “Return to Sender” sixteenth mission that Rocket Lab intends to recover fully intact. (Rocket Lab)
A glimpse of the Rocket Lab Electron booster of the “Return to Sender” sixteenth mission that Rocket Lab intends to recover fully intact. (Rocket Lab)

Like competitor SpaceX, Rocket Lab aims to recover its first stage Electron booster to decrease production time and increase launch cadence. Rocket Lab now has three launchpads to launch from and is licensed by the Federal Aviation Administration to carry out up to 130 launches per calendar year. In order to increase the launch cadence of the Electron, production times need to decrease. This can effectively be accomplished with the recovery, refurbishment, and reuse of the small, carbon composite rocket booster.

Recovery Doesn’t Happen Overnight

Initially, the first step of recovering an expended first stage – a guided and controlled soft water landing under a parachute and retrieval by sea-vessel – was intended for the seventeenth launch of the Electron prior to the end of this calendar year. However, Rocket Lab is now targeting the sixteenth launch for the first recovery attempt, a mission appropriately nicknamed “Return to Sender.” When asked what prompted the move to an earlier launch, Beck stated to reporters, “the guys got it done in time. With a new development like this, it’s always very dependent on how the program runs and the program ran very successfully.”

Rocket Lab has been working toward this recovery attempt for quite some time. In late 2018, Rocket Lab began collecting data during launches to inform future recovery efforts and determine whether or not it would even be feasible with a small-class rocket. The first major block upgrade of the Electron booster debuted on the tenth flight, “Running Out of Fingers,” in December 2019.

Rocket Lab’s first Electron booster to be outfitted with cold gas attitude control thrusters debuted in December 2019 during the first test of getting through “the wall.” (Rocket Lab)

The first recovery milestone, a task Beck called getting through “the wall,” was achieved following the tenth flight. And again in January 2020 following a successful eleventh flight of Electron. The “wall” Beck refers to is the Earth’s atmosphere. Returning a booster through the atmosphere intact requires extreme precision in terms of re-entry orientation and how efficient the heat shield is.

Because the Electron is a small-class rocket, Rocket Lab was able to collect enough data from previous flights to determine that the carbon composite frame could withstand a fall through the atmosphere given a precise enough angle of attack to sufficiently distribute thermal loads. According to Beck, the process is referred to as an “aero thermal decelerator.”

Following in SpaceX’s footsteps, Rocket Lab wants to become the second company in the world to reuse orbital-class rocket boosters. (USAF/Rocket Lab)

Small Rocket Following in Big Footsteps

SpaceX, Elon Musk’s space exploration company pioneered booster landing, recovery, and reuse efforts when the first Falcon 9 booster to successfully land returned to Landing Zone 1 at Cape Canaveral Air Force Station in Florida on December 21, 2015. SpaceX approaches the process of booster re-entry in a different way than what Rocket Lab has decided to attempt with Electron.

The Falcon 9 boosters perform a re-orientation flip and use the engines to perform what is known as a boost-back burn to set the rocket on the path to return to the Earth’s surface. The rocket then autonomously deploys titanium grid-fins that essentially steer, and slow the booster down as it falls through the atmosphere. Finally, the engines are re-ignited during a series of burns, and landing legs are deployed to propulsively land either at sea aboard an autonomous spaceport droneship or back on land at a landing zone.

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The booster of Rocket Lab’s tenth mission in 2019 was outfitted with guidance and navigation hardware and cold gas attitude control thrusters used to flip and orient the booster to withstand the stresses of re-entry. Otherwise, no other hardware was incorporated to reduce the stresses of re-entry or slow the vehicle as it fell through the atmosphere. The booster made it through “the wall” intact and eventually slowed to a rate less than 900km per hour by the time it reached sea-level for an expected impact.

Eventually, Rocket Lab imagines its small Electron booster to be caught during a controlled descent under parachute canopy with a specially equipped helicopter and grappling hook. Beck and his team spent weeks outfitting a test article with prototype parachutes that were manufactured in-house.

A low-altitude drop test of a test article to simulate an Electron first stage was performed and a helicopter was able to snag the test article mid-air and deliver it one piece. Essentially, this proved that the concept was at least feasible and the small-class rocket could in fact be fully recovered to eventually be refurbished and reused. Since the completion of this drop test in April of 2020, the parachute design has been reevaluated and many more drop tests have been conducted. The final drop test with a more traditional system of a drogue parachute and an 18m ringsail type main parachute occurred in August of 2020 with a first stage simulator.

Next up, Rocket Lab plans to use the finalized design of the parachute system to bring Electron home safely for a soft landing in the Pacific Ocean. After which the booster will be collected by a recovery vessel, similar to the process that SpaceX uses to scoop its payload fairings from the water.

The Rocket Lab Electron first stage booster intended for the sixteenth flight, “Return to Sender,” is seen being outfitted with parachute systems inside of the specially designated white interstage on the factory floor in Auckland, New Zealand. (Rocket Lab)

“Bringing a whole first stage back intact is the ultimate goal, but success for this mission is really about gaining more data, particularly on the drogue and parachute deployment system,” said Beck. With the parachute system verified the teams should be able to make any further iterations for a full capture and recovery effort on a future mission relatively quickly.

Rocket Lab will try to fully recover the “Return to Sender” expended first-stage booster once it separates approximately two and a half minutes after liftoff from Launch Complex 1 on the Mahia Penninsula of New Zealand. Electron will support a rideshare payload of thirty smallsats. The window to launch the sixteenth Electron mission opens on  November 16 UTC (November 15 PT / ET). A hosted live webcast of the launch and recovery attempt will be provided on the company website approximately fifteen minutes prior to liftoff.

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Tesla Model Y L gets suspension complaints in over odd issue China

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Credit: @TeslaNewswire/X

The Tesla Model Y L is arguably the most hyped trim of the all-electric crossover, other than the Performance configuration that comes with white-knuckle speed and sports car-level handling.

However, it is not all perfect. Tesla owners in China who took delivery of the Model Y L, denoted with an L to highlight its longer wheelbase, are experiencing what they are referring to as “collapsing” of the rear wheels, as suspension issues appear to be an issue with some of the builds.

The gap between the wheel arch and tire has narrowed to the point that “not even a single finger” could fit, according to a report from Car News China. The failures are not tied to a specific mileage, as one owner said that after just 9,000 kilometers (5,600 miles), they noticed the suspension issue when their car was fully loaded.

Another one had the issue at 30,000 kilometers (18,640 miles) and noticed that the wheel gap shrank to two fingers, so not as drastic as the person who reported a similar issue at 9,000 km.

Tesla Model Y L is gaining momentum in China’s premium segment

Along with the visual recognition of the issue, others are saying the sagging is causing abnormal wear on the inside of the tires. Extra weight and instant torque already provide additional stress on the tires in electric vehicles during normal operation, so it is no surprise that this is another complaint.

There has been no recall issued by Tesla, and the company has not yet publicly acknowledged the issue.

Some are suggesting that owners use a “finger test” to self-diagnose whether there is an issue with the suspension. There should be four fingers between the tire and the wheel well; anything less than that starts to get dicey.

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Tesla Cybercab event gains steam ahead of massive launch

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Credit: TechOperator | X

Tesla is starting to truly tease and hype its groundbreaking Cybercab event, which takes place tomorrow in Austin, Texas. It will be the first time members of the public will be able to ride in a Cybercab, a vehicle without any manual controls, on public roads.

Tesla has been dropping some hype on X over the past several days, but this morning, the excitement has truly started to build up for the event. Although Cybercab has been unveiled before, this is truly Tesla’s announcement that it is ready to start offering autonomous rides for public passengers in its new ride-hailing-geared vehicle for the first time.

The hype has started with a variety of different social media posts that are a true indication that Tesla is preparing for something big. Teasing so much of the potential of Cybercab, including its ability to truly revolutionize how people hail rides for local travel, is what the big idea for the event entails. The time that many Tesla owners, fans, and investors have been waiting for is potentially here:

The event has remained slim on details. Even invitees are still awaiting true details about what the event will entail, where they’ll go, and what is in store for the evening. This is pretty typical for an event run by Tesla; they keep things under wraps for the most part until the very last minute.

However, there is no secret about what the real intention of Tesla is for this event: it is going to be a huge reveal party for a vehicle that has no steering wheel and no pedals. It is a truly massive step for the company moving forward.

Speculation persists as to whether this is going to be an event that simply announces that rides will begin with the Cybercab, or it will be something more substantial. Tesla has said in the past that they plan to sell the Cybercab to the general public in what could become a great way to earn passive income by adding it to a more global fleet of Robotaxi-geared vehicles.

Tomorrow, the show begins in Austin, and the Cybercab goes live at some capacity; we just don’t know exactly how quite yet.

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SpaceX tells the FCC that Starship Flight 14 is going to orbit

SpaceX filed with the FCC for Starship Flight 14, its first true orbital launch attempt.

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SpaceX has asked the Federal Communications Commission for permission to fly Starlink terminals during Starship’s fourteenth flight test, and the filing lays out a genuine trip to orbit, something the program has never attempted.

Every Starship flight so far, including Flight 13’s successful splashdown in the Indian Ocean on July 24, has flown a suborbital arc that ends with the ship reentering the atmosphere within the same hour it launches. The FCC paperwork describes a mission profile built around an actual orbital insertion instead.

The payload is the other half of the story. Flight 13 carried 20 production Starlink V3 satellites, but because that mission never reached orbit, the satellites reentered along with the ship rather than joining the constellation, something Teslarati covered in detail after SpaceX released footage shot from one of those satellites as it drifted away from Starship in space. Flight 14 is designed to close that gap. If the orbital insertion holds, the roughly 20 V3 satellites onboard would separate into an operational orbit and could eventually go into service, each one rated for about 1 terabit per second of downlink capacity by SpaceX’s own account.

SpaceX announces new Starbase for ‘thousands of Starship launches annually’

Elon Musk first flagged the orbital attempt during SpaceX’s August 4 earnings call, the company’s first as a public entity following its June IPO under the ticker SPCX. He also floated catching the ship with the Starbase tower on the same flight, an idea he walked back on August 20, saying the catch attempt would more likely come “in a few months,” as Teslarati reported at the time. Flight 14 will instead target a splashdown for the ship in the Indian Ocean, the same recovery method used since Flight 12.

Hardware has been catching up to the ambition. Booster 21 completed a full 33-engine static fire on August 28, and Ship 41 finished its own six-engine test the week before. An airspace briefing circulated to pilots on August 20 listed September 15 as the target date, later than the end of August window Musk mentioned on the earnings call, though SpaceX has not confirmed a launch date publicly and Starship schedules routinely slip while hardware and FAA paperwork line up.

The FCC filing itself does not guarantee a launch date. It covers communications authority, and not flight readiness, considering SpaceX still needs Ship 41 fully stacked and cleared by the FAA before Flight 14 can fly. But the filing is a real marker of intent and it puts a specific regulatory process behind what had so far only been Musk’s word on the earnings call.

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