

News
US Air Force awards SpaceX $20m contract to support its biggest spy satellites
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.
- The large, white crawler underneath Falcon 9 is one of several methods of transportation SpaceX uses. (Instagram /u/robhubar)
- Falcon Heavy is composed of a Falcon 9 upper stage and three Falcon 9-class boosters. (SpaceX)
- The fully-integrated Falcon Heavy rolls out to Pad 39A. For vertical integration, think of this… but vertical. (SpaceX)
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.
Falcon Heavy goes vertical pic.twitter.com/uG1k0WISv1
— Elon Musk (@elonmusk) January 5, 2018
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.
- Elon Musk’s Roadster seen before being encapsulated in Falcon Heavy’s massive payload fairing. Below the Tesla is the payload adapter, which connects it to the rocket. (SpaceX)
- Imagine this building-sized fairing traveling approximately TWO MILES PER SECOND. (USAF)
- Finally, the fairing is transported vertically to the HIF, where it can be flipped horizontal and attached to its rocket. (Reddit /u/St-Jed-of-Calumet)
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.
- A hop and a skip south of 39A is SpaceX’s LC-40 pad. (SpaceX)
- Like all SpaceX pads, horizontal integration is a central feature. (SpaceX)
- LC-40’s brand new TEL carries a flight-proven Falcon 9 and Dragon out to the pad. (SpaceX)
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
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.
Under consideration. We’ve already stretched the upper stage once. Easiest part of the rocket to change. Fairing 2, flying soon, also has a slightly larger diameter. Could make fairing much longer if need be & will if BFR takes longer than expected.
— Elon Musk (@elonmusk) February 12, 2018
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
Pauline Acalin – Twitter
Eric Ralph – Twitter
News
SpaceX Ax-4 Mission prepares for ISS with new launch date
SpaceX, Axiom Space, and NASA set new launch date for the Ax-4 mission after addressing ISS & rocket concerns.

SpaceX is preparing for a new launch date for the Ax-4 mission to the International Space Station (ISS).
SpaceX, Axiom Space, and NASA addressed recent technical challenges and announced a new launch date of no earlier than Thursday, June 19, for the Ax-4 mission. The delay from June 12 allowed teams to assess repairs to small leaks in the ISS’s Zvezda service module.
NASA and Roscosmos have been monitoring leaks in the Zvezda module’s aft (back) segment for years. However, stable pressure could also result from air flowing across the hatch seal from the central station. As NASA and its partners adapt launch schedules to ensure station safety, adjustments are routine.
“Following the most recent repair, pressure in the transfer tunnel has been stable,” a source noted, suggesting the leaks may be sealed.
“By changing pressure in the transfer tunnel and monitoring over time, teams are evaluating the condition of the transfer tunnel and the hatch seal between the space station and the back of Zvezda,” the source added.
SpaceX has also resolved a liquid oxygen leak found during post-static fire inspections of the Falcon 9 rocket, completing a wet dress rehearsal to confirm readiness. The Ax-4 mission is Axiom Space’s fourth private astronaut trip to the ISS. It will launch from NASA’s Kennedy Space Center in Florida on a Falcon 9 rocket with a new Crew Dragon capsule.
“This is the first flight for this Dragon capsule, and it’s carrying an international crew—a perfect debut. We’ve upgraded storage, propulsion components, and the seat lash design for improved reliability and reuse,” said William Gerstenmaier, SpaceX’s vice president of build and flight reliability.
The Ax-4 mission crew is led by Peggy Whitson, Axiom Space’s director of human spaceflight and former NASA astronaut. The Ax-4 crew includes ISRO astronaut Shubhanshu Shukla as pilot, alongside mission specialists Sławosz Uznański-Wiśniewski from Poland and Tibor Kapu from Hungary. The international team underscores Axiom’s commitment to global collaboration.
The Ax-4 mission will advance scientific research during its ISS stay, supporting Axiom’s goal of building a commercial space station. As teams finalize preparations, the mission’s updated launch date and technical resolutions position it to strengthen private space exploration’s role in advancing space-based innovation.
News
Sweden blocks Tesla FSD-style testing in Stockholm
It looks like FSD testing in Sweden would have to wait some time.

Tesla is putting a lot of effort into getting its Full Self Driving (FSD) system approved in territories outside North America. But while China seems to have embraced FSD fully, other countries like Sweden do not seem to be receiving Tesla’s automated driving system very well.
This became quite evident in a document from Stockholm City, which has started making the rounds online.
FSD Testing Rejected
The document, which was initially shared by X user @KRoelandschap, indicated that the Swedish Traffic Department in Stockholm had rejected Tesla’s request to start FSD testing in the city’s streets. Tesla has been demonstrating FSD in several areas across Europe, so it is not surprising that the company is also attempting to test its automated driving system in Sweden.
Unfortunately for Tesla, Sweden might prove to be a tough nut to crack. As per the City of Stockholm:
“The Traffic Office is currently working on updating its approach to automation. At the same time, the city and the office are under heavy pressure from other ongoing innovation tests. Our ambition is to actively participate in and learn from the continued development in the field of automation.
“Based on this, and in combination with the fact that the current test is the first of its kind, which entails certain risks for both infrastructure and third parties, and that it is planned to be carried out throughout the city, the City of Stockholm considers it is currently not possible to approve the implementation of the test.”
Tesla’s Other Swedish Troubles
Sweden’s FSD testing rejection is not the only roadblock facing Tesla in the country. Since October 2023, Swedish unions have been engaged in an active effort to disrupt Tesla’s operations. The unions’ efforts have been varied, with some resulting in Tesla having difficulty launching more Superchargers in Sweden. Despite this, Tesla has remained stubborn and has refused to bow to the unions’ demands.
Fortunately for Tesla, it seems like its numbers are still strong. Despite the company’s decline in several European countries, the new Model Y is starting to see strong sales figures in Sweden. In early May alone, the new Model Y became the country’s most popular electric vehicle—a notable accomplishment considering the unions’ active efforts to disrupt Tesla.
News
Tesla firmware shows new Model Y seat configuration is coming
Tesla could be adding another seating configuration beside the seven-seater to the Model Y lineup later this year.

Tesla firmware has been a great place for some to reveal what the company has in the pipeline, and a new seating configuration for the best-selling Model Y looks to be on the way.
Last week, we reported that Tesla was already hinting toward a 7-seater configuration of the Model Y in a promotional email it sent to those on its contact list.
However, firmware revealed by Tesla hacker greentheonly is showing that a new seating configuration is on the way — a six-seater:
The much rumored about 6-seater Model Y made an appearance in the firmware.
Unlikely to be China-only as some of the speculations said.Some weird “slow down to save energy, people typically drive this much slower here to save %%” nav suggestions.
— green (@greentheonly) June 16, 2025
Green says the configuration would not be available in China-only, and will be potentially for sale in other markets as well.
The six-seat and seven-seat configurations of the Model Y were available in the Legacy version of the vehicle, but were met with mixed reviews, as many complained about the lack of legroom in the third row.
This was something that was a real concern for many of those owners who needed something larger than the traditional five-seat variant, but did not want to buy the much more pricey Model X.
We’ve covered the size of that third row on several occasions.
Some owners even took the idea of having a seven-seater into their own hands:
Tesla Model Y third row seat test explores options for a comfortable 7-seat setup
Tesla did not explicitly announce a six-seater configuration of the Model Y, but Lars Moravy, the company’s VP of Vehicle Engineering, said the seven-seater would come to production later in 2025.
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