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SpaceX may have signed a fairing agreement with ULA supplier RUAG (Update: no agreement)

Falcon 9 and Heavy use the same custom-built fairing but SpaceX is reportedly interested in buying taller fairings from prominent ULA supplier RUAG. (SpaceX/ULA)

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According to unverified and speculative comments reportedly made to a member of the space industry by a RUAG spokesperson, the prominent aerospace supplier may have reached an agreement with SpaceX to manufacture a handful of larger payload fairings for future Falcon 9 and Heavy launches.

In the likely event that SpaceX is one of two contractors awarded a portion of several dozen US military launch contracts next year, the company will need to be able to cater to niche requirements, including accommodating unusually tall military satellites. Those satellites can be so tall that SpaceX’s own payload fairing – generally middle-of-the-pack relative to competitors’ offerings – may be too short, meaning that SpaceX will have to find ways around that minor shortcoming.

Update: Tim Chen has retracted his earlier comments and has stated that there is actually no agreement currently in place with SpaceX for RUAG to produce taller fairings out of its new Decatur, AL factory.

Additionally, ULA CEO Tory Bruno clarified that the company’s “[new fairing] has [ULA] intellectual property in its design and manufacture … [and] is currently planned only for use on Atlas and Vulcan”, meaning that any cooperation between SpaceX and RUAG would likely require a new production facility and a somewhat different fairing design.

“ULA’s new fairing, which is built in our factory in Decatur, has our intellectual property in its design and manufacture. This fairing is currently planned only for use on Atlas and Vulcan. You would want to ask RUAG about business they might have with their other customers.”

Tory Bruno, August 14th, 2019

https://twitter.com/timothytchen1/status/1161261562713137153

Regardless of the veracity of these recent claims, it appears that SpaceX has three obvious responses at its disposal: design and build an entirely new variant of its universal Falcon fairing, purchase the necessary fairings from an established supplier, or bow out of launch contract competitions that demand it. The latter option is immediately untenable given that it could very well mean bowing out of the entire US military competition, known as Phase 2 of the National Security Space Launch program’s (NSSL; formerly EELV) Launch Services Procurement (LSP).

For dubious reasons, the US Air Force (USAF) has structured the NSSL Phase 2 acquisition in such a way that – despite there being four possible competitors – only two will be awarded contracts at its conclusion. The roughly ~30 launch contracts up for grabs would be split 60:40 between the two victors, leaving two competitors completely emptyhanded. In short, bowing out of the Phase 2 competition could mean forgoing as many as one or two-dozen contracts worth at least $1-2B, depending on the side of the 60:40 split.

A side-by-side comparison of Blue Origin, SpaceX, and ULA fairings, roughly to scale. (Teslarati)

According to a handful of recent comments and developments, SpaceX has likely sided with the option of procuring taller fairings from an industry supplier. As it turns out, European company RUAG has effectively cornered the Western rocket fairing market, with SpaceX being the only Western launch company currently building its own fairings. RUAG builds fairings for both Arianespace’s Ariane 5 and Vega rockets and ULA’s Atlas V. Additionally, RUAG will build and supply fairings for both companies’ next-gen rockets – Arianespace’s Ariane 6 and ULA’s Vulcan – and builds fairings for a number of smallsat launch companies.

Comments made in June by a RUAG official confirmed that there was some semblance of a relationship between SpaceX and RUAG for the purpose of satisfying USAF needs for taller fairings, although the phrasing suggested that the cooperation was in its early stages and nothing had been solidified.

“In a June 12 letter to Smith, the company’s CEO Peter Guggenbach makes the case that legislation forcing access to suppliers is unnecessary in this case because RUAG does not have an exclusive arrangement with ULA and is willing to work with SpaceX or any other launch providers.

“For this competition, we are in the process of submitting or have submitted proposals to multiple prime contractors regarding launch vehicle fairings. In those agreements, we share technical data to support a prime contractor’s bid while protecting our intellectual property.”

RUAG vice president Karl Jensen told 
SpaceNews the company has a “significant partnership” with ULA but is looking to work with others too. “We have an offer to SpaceX,” he said. “We don’t know if they’ll accept it.”

SpaceNews, 06/13/2019

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RUAG (right) builds payload fairings for Ariane 5/6, Delta IV, Atlas V, and Vulcan. SpaceX (left) builds its own Falcon fairings in-house. (SpaceX/RUAG)

Interestingly, although ULA’s RUAG-built Atlas V fairing is slightly narrower than SpaceX’s 5.2m (17 ft) diameter fairing, Atlas V’s largest fairing is significantly taller, supporting payloads up to 16.5m (54 ft) tall compared to 11m (36 ft) for Falcon 9 and Heavy. Given that just a tiny portion of military spacecraft actually need fairings that tall, SpaceX is apparently not interested in simply modifying its own fairing design and production equipment to support a 20-30% stretch.

This likely relates in part to the fact that one of SpaceX’s three NSSL Phase 2 competitors – Northrop Grumman (Omega), Blue Origin (New Glenn), and ULA (Vulcan) – are guaranteed to receive hundreds of millions of dollars of development funding after winning one of the two available slots (60% or 40% of contracts). SpaceX, on the other hand, will receive no such funding while still having to meet the same stringent USAF requirements compete in LSP Phase 2. Of note, Congressman Adam Smith managed to insert a clause into FY2020’s defense authorization bill that could disburse up to $500M to SpaceX in the event that the company is one of Phase 2’s two winners.

SpaceX builds all large Falcon 9 and Heavy composite structures in house, including landing legs, interstages, and payload fairings. (SpaceX, 2016)

Despite this potential influx of infrastructure-focused funds, SpaceX may still be pursuing taller Falcon fairings from RUAG as a backup in the event that the company is not one of the two Phase 2 winners or is unable to use some of the $500M secured by Rep. Smith to develop its own stretched fairing.

On August 12th, SpaceX – along with Blue Origin, ULA, and NGIS – submitted bids for NSSL Phase 2 launch services, confirming that all four companies will indeed be in the running for contracts. The USAF is not expected to announce the results of this competition until Q2 2020.

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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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Elon Musk drops a surprise update on Boring Company’s next big dig

Musk says Boring Company could shrink the Austin to San Antonio drive to just minutes.

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Elon Musk says The Boring Company is working on what he called “a simple, precursor Hyperloop” tunnel connecting Austin and San Antonio, targeting speeds above 200 mph and cutting a drive that can take up to two and a half hours down to a consistent under 30 minutes. Musk posted the idea on X Sunday, in a reply to a repost of an AI generated video imagining a science fiction future with human colonies on other worlds, which he shared with the line “This is the future we shall bring into being.”


The Boring Company’s own account picked up the idea in the same thread, adding a detail about how the trip would actually work: “Because Loop/Hyperloop is express (i.e. no intermediate stops), one could travel from an Austin parking lot to a favorite San Antonio restaurant in about 30 minutes. As long as they both have Loop stations.” That framing ties the proposed intercity link to the same station model the company already runs in Las Vegas, where riders enter the tunnel network through small, garage style stops rather than one central terminal.

This is not the company’s first run at the Austin to San Antonio corridor. Boring Company floated tunnels between the two cities as far back as 2021, and later competed for a separate San Antonio Loop project tied to the airport before that specific bid stalled. Pitches for tunnels in Chicago, Los Angeles, and a New York to Washington corridor have followed a similar pattern of big announcement without a shovel in the ground.

What is different this time is the balance sheet, especially since The Boring Company closed a 3 billion dollar funding round led by investors in the United Arab Emirates earlier this month at a valuation near 23 billion dollars, giving the tunneling company more capital to chase speculative projects than it had during its earlier Texas pitches. The company is also mid-build on two other intercity systems it has actually broken ground on, inc;luding a Nashville tunnel linking downtown to the airport, where a second boring machine finished commissioning in June, and its Las Vegas network, where the station count keeps climbing on paper faster than tunnels get dug.

That gap between announcement and execution is the reason to treat Sunday’s post as an opening bid rather than a project. A tunnel spanning roughly 80 miles between two metro areas, running at speeds Boring Company has not demonstrated over any real distance, would dwarf anything the company has built. For now, the Austin to San Antonio Hyperloop exists as a caption under an AI generated space video.

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Tesla eyes supply partners for Optimus mass production

Tesla certified three Chinese suppliers for Optimus mass production, signaling its robot timeline is accelerating.

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Concept rendering of Tesla Optimus in mass production

Tesla’s robotics team traveled to Ningbo, in China’s Zhejiang province, on September 16 and spent the following day auditing component suppliers for Optimus, according to a Bloomberg report cited by RobotAIGeek. The visit moved three manufacturers from provisional status to certified mass production partners: Tuopu Group, which handles actuators and chassis components, Ningbo Joyson Electronic, a sensor supplier, and Zhejiang Sanhua Intelligent Controls, which builds thermal management systems. All three already supply parts to Tesla’s electric vehicles, and the audit reportedly came with fresh orders that supply chain reports put at an initial batch of roughly 5,000 units.

Tuopu, Joyson, and Sanhua built their manufacturing base serving the automotive industry, where tolerances and volume requirements are already close to what a mass produced humanoid robot demands. Sanhua in particular has history here. Teslarati reported last October that the company had received a roughly $685 million order for linear actuators tied to Optimus, a volume industry watchers estimated could cover around 180,000 robots once production ramped.

Supply chain reports tied to this week’s audit put Tesla’s near term production goal at about 1,000 Optimus units a week by late September, rising to 2,000 to 2,500 units a week by the end of the year. That pace would put real weight behind the timeline Tesla has been building toward since May, when it wound down Model S and Model X production at Fremont to convert that floor space into a dedicated Optimus line targeting one million units annually. JPMorgan analysts who toured the factory in August confirmed the conversion took roughly four months, a pace Musk has called unprecedented for a facility that size.

New drone video shows Tesla’s Optimus Factory reaching a turning point

Fremont is only the first phase. A second, larger Optimus plant is rising at Gigafactory Texas, where drone footage shared by Joe Tegtmeyer last week showed the structural steel nearing completion on the north end of the building. Tesla has said that facility is meant to eventually support production of up to 10 million units a year, though volume output there is not expected before 2027.

Commercial sales of Optimus are still targeted for the second half of 2027, but production is expected to start well before then. JPMorgan analyst Rajat Gupta has said Tesla’s “Optimus Academy” program, which uses early units to collect real world training data inside Tesla’s own facilities, is expected to be running later this year. Bloomberg Intelligence analyst Ian Ma described the Ningbo audits as “a positive commercialization signal for China’s humanoid supply chain,” noting that sentiment could improve further if the visit leads to confirmed supplier nominations and larger orders. The Solactive China Humanoid Robotics Index rose about 1.4% on the news, though it remains down roughly 30% for the year.

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Elon Musk’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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