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US Air Force awards SpaceX $20m contract to support its biggest spy satellites

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9 years ago

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Slipping beneath the watchful eye of many skilled defense journalists, the government contracting database FPDS.gov indicates that the US Air Force awarded SpaceX more than $20 million in November 2017 to conduct a design study of vertical integration capabilities (VIC). Describing what exactly this means first requires some background.

Vertical whaaaat?

The flood of acronyms and technical terminology that often follow activities of the Federal government should not detract from the significance of this contract award. First and foremost, what exactly is “vertical integration” and why is significant for SpaceX? Not to be confused with more abstract descriptions of corporate organization (vertical integration describes one such style), integration here describes the literal process of attaching satellite and spacecraft payloads to the rockets tasked with ferrying them to orbit.

Likely as a result of its relative simplicity, SpaceX has used a system of horizontal integration for as long as they have been in the business of launching rockets, be it Falcon 1, Falcon 9, or Falcon Heavy. In order to integrate payloads to the rocket horizontally, SpaceX has a number of horizontal integration facilities (HIF) directly beside each of their three launch pads – two in Florida, one in California. After being transported from the company’s Hawthorne, CA rocket factory, Falcon 9 and Heavy boosters, second stages, payload fairings, and other miscellaneous components are all brought into a HIF, where they are craned off of their transporters (a semi-trailer in most cases) and placed on horizontal stands inside the building.

While in the HIF, all three main components are eventually attached together (integrated). The booster or first stage (S1) has its landing legs and grid fins installed soon after arrival at the launch site, followed by the mating of the first and second stages. Once these two primary components of the rocket are attached, the entire stack – as the mated vehicle is called – is once again lifted up by cranes inside the facility and placed atop what SpaceX calls the strongback (also known as the Transporter/Launcher/Erector, or TEL). A truly massive steel structure, the TEL is tasked with carrying the rocket to the launch pad, typically a short quarter mile trek from the integration facility. Once it reaches the pad, the TEL uses a powerful hydraulic lift system to rotate itself and its rocket payload from horizontal to vertical. It may look underwhelming, but it serves to remember that a complete Falcon 9/Heavy and its TEL are both considerably more than twice as tall as a basketball court is long.

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Once at the pad, the TEL serves as the rocket’s connection to the pad’s many different ground systems. Crucially, it is tasked with loading the rocket with at least four different fuels, fluids, and gases at a broad range of temperatures, as well as holding the rocket down with giant clamps at its base, providing connection points to transmit a flood of data back to SpaceX launch control. SpaceX’s relatively unique TEL technology is to some extent the foundation of the company’s horizontal integration capabilities – such a practice would be impossible without reliable systems and methods that allow the rocket to be easily transported about and connected to pad systems.

Still, after the Amos-6 mishap in September 2016, which saw a customer’s payload entirely destroyed by a launch vehicle anomaly ahead of a static fire test, SpaceX has since changed their procedures, and now conducts those static fire tests with just the first and second stages – the payload is no longer attached until after the test is completed. For such a significant decrease in risk, the tradeoff of an additional day or so of work is minimal to SpaceX and its customers. Once completed, the rocket is brought horizontal and rolled back into the HIF, where the rocket’s payload fairing is finally attached to the vehicle while technicians ensure that the rocket is in good health after a routine test-ignition of its first stage engines.

Before being connected to the rocket, the payload itself must also go through its own integration process. Recently demonstrated by a flurry of SpaceX images of Falcon Heavy and its Roadster payload, this involves attaching the payload to a payload adapter, tasked with both securing the payload and fairing to the launch vehicle. Thankfully, the fairing is far smaller than the rocket itself, and this means it can be vertically integrated with the payload and adapter. The final act of joining and bolting together the two fairing halves is known as encapsulation – at which point the payload is now snug inside the fairing and ready for launch. Finally, the integrated payload and fairing are lifted up by cranes, rotated horizontally, and connected to the top of the rocket’s second stage, marking the completion of the integration process.

A different way to integrate

Here lies the point at which the Air Force’s $20m contract with SpaceX comes into play. As a result of certain (highly classified) aspects of some of the largest military satellites, the Department of Defense (DoD) and National Reconnaissance Office (NRO) prefer or sometimes outright require that their payloads remain vertical while being attached to a given rocket. The United Launch Alliance (ULA), SpaceX’s only competition for military launches, almost exclusively utilizes vertical integration for all of their launches, signified by the immense buildings (often themselves capable of rolling on tracks) present at their launch pads. SpaceX has no such capability, at present, and this means that they are effectively prevented from competing for certain military launch contracts – contracts that are often the most demanding and thus lucrative.

It’s clear that the Air Force itself is the main impetus pushing SpaceX to develop vertical integration capabilities, a reasonable continuation of the military’s general desire for assured access to orbit in the event of a vehicle failure grounding flights for the indefinite future. For example, if ULA or SpaceX were to suffer a failure and be forced to ground their rockets for months while investigating the incident, the DoD could choose to transfer time-sensitive payload(s) to the unaffected company for the time being. With vertical integration, this rationale could extend to all military satellites, not simply those that support horizontal integration.

Fittingly, the ability to vertically integrate satellites is likely a necessity if SpaceX hopes to derive the greatest possible value from its recently and successfully introduced Falcon Heavy rocket, a highly capable vehicle that the government is likely very interested in. Although the specific Air Force contract blandly labels it a “Design Study,” (FPDS.gov account required) its hefty $21 million award may well be far more money than SpaceX needs to design a solution. In fact, knowing SpaceX’s famous ability to develop and operate technologies with exceptional cost efficiency, it would not be shocking to discover that the intrepid launch company has accepted the design study grant and instead jumped head-first into prototyping, if not the construction of an operational solution. More likely than not, SpaceX would choose to take advantage of the fixed tower (known as the Fixed Service Structure, FSS) currently present at Pad 39A, atop which a crane and work platforms could presumably be attached

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Intriguingly, it is a real possibility that Fairing 2.0 – its first launch scheduled to occur as early as Feb. 21 – could have been upgraded in part to support present and future needs of the Department of Defense, among numerous other benefits. Fairing 2.0’s larger size may have even been precipitated by physical requirements for competing for and dealing with the largest spysats operating by the DoD and NRO, although CEO Elon Musk’s characterization of that change as a “slightly larger diameter” could suggest otherwise. On the other hand, Musk’s offhand mention of the possibility of significantly lengthening the payload fairing is likely aimed directly at government customers in both the civil and military spheres of space utilization. Time will tell, and it certainly will not hurt SpaceX or its customers if Fairing 2.0 is also considerably easier to recover and reuse.

Ultimately, it should come as no surprise that SpaceX would attempt to leverage this contract and the DoD’s interest in ways that might also facilitate the development of the company’s futuristic BFR rocket, intended to eventually take humans to the Moon, Mars, and beyond. As shown by both 2016 and 2017 iterations of the vehicle, it appears that SpaceX intends to use vertical integration to attach the spaceship (BFS) to the booster (BFR). While it’s unlikely that this Air Force contract will result in the creation of a vertical integration system that could immediately be applied to or replicated for BFS testing, the experience SpaceX would gain in the process of building something similar for the Air Force would be invaluable and essentially kill two birds with one stone.

While now outdated, SpaceX’s 2016 Mars rocket featured a giant crane used for vertical integration. BFR appears to use the same approach. (SpaceX)

Follow along live as I and launch photographers Tom Cross and Pauline Acalin cover these exciting proceedings live and in person.

Teslarati   –   Instagram – Twitter

Tom Cross – Twitter

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Pauline Acalin – Twitter

Eric Ralph – Twitter

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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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SpaceX makes history, catching Starship from orbit for the first time

SpaceX caught Starship’s upper stage with its launch tower for the first time on Saturday.

Published

8 hours ago

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November 14, 2026

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Ship 42 fires its engines as it descends toward the Starbase launch tower’s chopstick arms, moments before SpaceX caught a Starship upper stage for the first time on Flight 15. (Credit: SpaceX)
Ship 42 fires its engines as it descends toward the Starbase launch tower’s chopstick arms, moments before SpaceX caught a Starship upper stage for the first time on Flight 15. (Credit: SpaceX)

SpaceX caught a Starship upper stage with its launch tower for the first time on Saturday, bringing Ship 42 back to Starbase after roughly 22 and a half hours in orbit on Flight 15. No company has ever returned the upper stage of an orbital rocket to its launch site and caught it.

Ship 42 lifted off Friday evening on top of Booster 22, reached orbit and deployed all 26 of its Starlink V3 satellites. Three of those satellites carried cameras to photograph the ship’s heat shield, and SpaceX said the imagery showed it was in good shape for reentry, allowing controllers to pass on a backup splashdown option overnight. By Saturday morning, SpaceX posted on X that “Pad and tower systems are go for catch.” After about 14 orbits, the ship fired its engines to leave orbit, came back through the atmosphere and was caught by the tower’s chopstick arms.

 

The catch salvages a flight that started with a setback. Super Heavy did not make it back to the tower on Friday. “We were initially go for a catch, but in the later stages of the coast, the booster aborted itself for a GNC issue that it detected and that put it into its landing offshore,” SpaceX’s Dan Huot said. The booster hovered over the Gulf of Mexico before its flight termination system triggered and it came down in the water.

Elon Musk said Saturday that the booster ran short on propellant because its engines slightly underperformed. The fix, he wrote, is better engine consistency with Raptor V3.2 and a flight software change to cut the engines “about one second earlier” so enough fuel is left for the return. “This booster loss does not change our timeline to reach high volume, fully reusable Starship flights,” Musk added.

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The ship is the harder half of that goal, and the one SpaceX had never recovered. Super Heavy has now been caught three times, most recently in March 2025, while every previous ship ended in the ocean or was lost. Falcon 9 lands its boosters routinely but throws its upper stage away on every launch. Musk described a full Starship recovery on SpaceX’s third quarter earnings call as a “profound technology milestone,” and Saturday’s catch shows the hardest piece of it can work.

That piece matters for nearly everything SpaceX is planning. Reusable ships are what make the economics of launching Starlink V3 satellites at scale work, along with the Starmind orbital compute constellation. NASA’s Artemis lunar lander also depends on refilling Starships in orbit with repeated tanker flights, which requires vehicles that can fly again quickly. Musk has said he expects Starship to reach a weekly launch cadence in the first half of 2027.

Flight 15 also improved on the last Starship mission in September, which reached orbit but ended after about three hours with a Pacific splashdown when some engines shut down. Before this flight, SpaceX had shown an animation of the ship catch during its earnings webcast, and Musk put the odds of pulling it off on the first try at “more likely than not,” as Teslarati reported.

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Tesla Cybercab ownership will come with plenty of strings attached

Published

16 hours ago

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November 14, 2026

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Credit: Tesla

Tesla’s long-promised Cybercab is finally available for personal purchase, at least for a select few in the Austin area. But it’s far from a straightforward ownership experience.

The $29,990 price tag comes with a stack of restrictions that redefine what “owning” the vehicle actually means. The two-seat, steering-wheel-free Robotaxi, previously limited to Tesla’s own fleet, now carries contractual terms that limit where it can go, how it can be used, and whether it can even move without an active paid subscription.

Opening Night of Orders

Late on November 13, Tesla announced that select customers were being invited to order a Cybercab for personal use.

Tesla Cybercab goes on sale for $29,990, slated for December deliveries

The estimated purchase price is $29,990 before taxes, paired with a non-refundable $1,000 deposit and an estimated December 2026 delivery in Austin, Texas. The first month of the required :Autonomy Subscription,” priced at $299 per month is included.

After that, the vehicle needs an active subscription to operate at all. The announcement confirmed that customer sales had begun, albeit on an invite-only basis rather than a public order page.

The Fine Print for Buyers

For those invited to order, the agreements (Cybercab Order Agreement, Terms of Use, and Autonomy Subscription Agreement) impose significant constraints. Major points include:

  • A mandatory Autonomy Subscription (currently listed at $299 per month on the order screen, first month included) is required; without it, the Cybercab will not operate.
  • Personal, non-commercial use only; ride-hailing, Robotaxi network participation, delivery, or rental requires separate written authorization or product enablement from Tesla.
  • Operation restricted to Tesla-enabled Robotaxi geofences and supported service areas, which the company can expand, shrink, or alter; the vehicle may be technologically prevented from operating outside them.
  • No unauthorized modifications (including wraps, window tint, or wheel changes) without Tesla or an authorized provider.
  • Restricted resale and transfer: written permission required, with contractual damages of at least $50,000 (or full transaction value if higher) for unauthorized sales; Tesla also reserves repurchase rights at a company-determined fair market value, with the owner covering return costs.
  • Safety or improper-use “strikeouts” (three or more) can trigger a one-week suspension of autonomous features without prorated refund.
  • Owners remain responsible for insurance, registration, charging, parking, and general cleaning; the subscription covers certain maintenance items such as tires, windshields, filters, and camera cleaning, plus limited towing.
  • Manual controls on the touchscreen allow only short-distance movement up to about 2 mph and require a valid driver’s license; they are not for public-road driving.

Why These Terms Might Exist

Tesla’s approach prioritizes control over a vehicle designed without traditional human controls and intended primarily as transport-as-a-service, something that Musk has hinted toward for some time now. Restricting commercial use and modifications could be as much of a software integrity, safety, and data collection effort as it is a safety effort.

Fleet consistency could also be in regulatory scrutiny early on in the Cybercab’s days of public operation.

The subscription model generates ongoing revenue beyond the low vehicle price and ensures the car remains connected and updatable, something that will keep the Cybercab as safe as possible as new updates roll out.

Buyback and resale limits reduce the risk of vehicles circulating outside Tesla’s operational and service ecosystem.

It apperas that personal ownership is secondary to the broader Robotaxi network strategy, as Musk has previously stated that the vast majority of Cybercabs would remain Tesla-owned.

Pickup Locations and Musk’s Pricing View

Initial deliveries are estimated for Austin, but personal vehicles are able to operate in any of Tesla’s Robotaxi geofences:

Those who have been invited to order can also have their personal Cybercab delivered to numerous locations in Texas, including:

  • Austin
  • Dallas
  • Houston
  • San Antonio
  • Fort Worth

As far as the monthly “Autonomy Subscription,” it appears Musk already wants it to be low. He acknowledged last night on X that the subscription price is too high. Along with detailing that the Cybercab will be available nationwide as regulatory approval is received, Musk said the monthly fee should match the cost of FSD and Premium Connectivity, which is about $115 per month.

The launch marks a milestone for unsupervised personal autonomous vehicles, but the fine print makes clear that buyers are purchasing a highly constrained asset whose usefulness is tightly bound to Tesla’s software, service network, and geographic approvals.

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Tesla Cybercab goes on sale for $29,990, slated for December deliveries

Published

1 day ago

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November 13, 2026

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Credit: Tesla

Tesla has officially put the Cybercab up for sale, revealing a bargain price and a $299 per month “Autonomy Subscription” that could hit customer hands as soon as December.

The offer requires a $299 monthly Autonomy Subscription, with the first month included in the purchase price, along with a $1,000 non-refundable order deposit. Tesla’s ordering interface shows deliveries targeted for Austin, Texas.

Tesla says that the Cybercab is making transportation more efficient, affordable and accessible than ever before, and that buyers can order their own Cybercab for personal use.

The Cybercab is Tesla’s dedicated robotaxi, a gold-finished, two-passenger vehicle without a steering wheel or pedals, designed from the outset for unsupervised autonomous operation. It has been in limited Robotaxi service in Austin since September 2026, operating alongside Tesla’s larger fleet of Model Y vehicles.

Production takes place at Gigafactory Texas, which launched earlier this year. Tesla has stated for some time that it planned to put Cybercabs on sale by the end of the year, and it looks like they will come through on that promise if everything goes according to plan.

The Autonomy Subscription is mandatory for the vehicle to operate because it is void of a steering wheel and pedals. Tesla notes that the subscription and regular vehicle maintenance are required, indicating that personal owners will depend on the company’s software and service infrastructure rather than traditional ownership models.

One month of the subscription is included with purchase and subsequent months are billed separately until canceled.

This limited personal-sales opening marks a shift from Tesla’s earlier emphasis on fleet and transport-as-a-service operations. During the Q3 2026 Earnings Call, executives indicated that the vast majority of Cybercabs would remain Tesla-owned and used for rideshare service, while still aiming to place some vehicles with customers by year-end.

Elon Musk has previously targeted a price below $30,000, which was a huge point of emphasis for the Cybercab being the central point of Tesla’s “transportation-as-a-service” model.

Availability remains restricted to invited customers rather than a public order page, and the initial deliveries are expected only in the Austin area where unsupervised Robotaxi operations are already active. Buyers will need to accept the geographic and operational constraints of current autonomous deployment, as the vehicle cannot be driven manually outside supported zones.

The move gives a small number of early buyers the chance to own Tesla’s dedicated autonomous vehicle at the long-discussed sub-$30,000 price point, while the bulk of production continues to support the company’s expanding Robotaxi network.

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