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SpaceX prepares to break ground on Starship launch facilities at Pad 39A

SpaceX has plans to modify Pad 39A to simultaneously support launches of Starship/Super Heavy and Falcon 9/Heavy. (SpaceX)

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As of September 14th, SpaceX is nearly ready to break ground on what will likely be the first orbital-class Starship and Super Heavy launch pad, coming in the form of an addition to the company’s NASA-leased LC-39A pad at Kennedy Space Center.

Based on environmental assessment documents published in August 2019, the modifications SpaceX plans to make to Pad 39A are surprisingly minor and could arguably take just a handful of months from start to finish. Once complete, SpaceX will possess dedicated Starship launch facilities in both Florida and Texas, although there is a strong chance that Pad 39A will be ready to support orbital launch attempts well before SpaceX’s Boca Chica launch site is certified.

Per NASASpaceflight.com’s Kennedy Space Center (KSC) sources, the new activity and equipment at Pad 39A was confirmed to be the start of Starship-related modifications. However, the basic location of the new activity supports the theory that the work is Starship-related irrespective of any sourced confirmation.

Maps published in an August 2019 Draft Environmental Assessment (EA) show that SpaceX is currently staging construction materials and equipment in the same quadrant that a majority of Starship’s Pad 39A ground systems will eventually be located. According to the draft EA, SpaceX will likely continue to use its existing 39A hangar, additionally supported by a comment from CEO Elon Musk indicating that Starship and Super Heavy will be more or less structurally stable in horizontal positions. The 39A hangar is large enough to house Starships and Super Heavy boosters, although their presence would almost certainly impact Falcon 9/Heavy operations

Still, Starship and Super Heavy will be vertically integrated into a single ‘stack’ prior to launch. According to SpaceX, a large, mobile crane will be used temporarily and will eventually be replaced with a permanent, fixed-structure crane at some point in the future. Aside from a propellant farm and associated plumbing for Starship’s liquid methane fuel supply, the EA shows plans for new water percolation and retention ponds, as well as a new landing zone located just a few hundred feet away from the planned launch mount.

LZ-1 and LZ-2, circa February 2018. (SpaceX)

Until the FAA performs an environmental assessment of rocket landings at Pad 39A, SpaceX will land Starships at its established LZ-1/2 landing zones, while Super Heavy will be exclusively recovered via drone ship until SpaceX has permission to literally perform return to launch site (RTLS) landings.

As with most SpaceX projects, Pad 39A’s Starship-related development is effectively structured in phases. The first phase focuses primarily on suborbital Starship flight tests and will require a relatively spartan launch mount/stand and water-cooled thrust diverter. SpaceX is in the middle of preparing to build the concrete foundation that said Starship launch mount and deluge system will be installed on. Once SpaceX is ready for orbital Starship launch attempts (and thus Super Heavy booster involvement), the company will either stretch the existing launch mount a dozen or so meters taller or build a new structure tall enough to prevent Super Heavy from destroying the concrete foundation.

That latter task will be quite the challenge, given that a full-up Super Heavy booster at full thrust could produce almost twice as much thrust as NASA’s Saturn V rocket, the massive launch vehicle Pad 39A was originally built to support. According to Elon Musk, Starship’s first orbital launch attempt(s) could begin as early as November or December 2019, although sometime in Q1 or Q2 2020 is a far safer bet. Either way, it’s possible that SpaceX will transport Starship Mk2 to Pad 39A as early as this month (September 2019) and the first launch of a Starship prototype (likely Mk1) is scheduled as early as October 13th. Starship Mk2 could be ready for its own flight debut soon after.

Stay tuned as SpaceX continues to fire on all cylinders in pursuit of its fully-reusable, next-generation launch vehicle.

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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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Tesla just told us twice that Model Y L is coming to the U.S.

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Credit: Tesla

Tesla just told us twice that the Model Y L is coming to the U.S., and two social media posts definitely just tipped the company’s hand, as if they wanted it to be any other way.

The two social media posts basically confirm that the slightly longer version of the Model Y will be heading to the United States soon, and many have speculated that the company could launch the vehicle as soon as this weekend.

The first post was directly from Tesla, and it showed an incredibly long Dachshund, with words above that said, “Looking forward to the long weekend.”

Anyone who knows Tesla knows the company loves to troll its fans and have fun, and this is a perfect example of that. While not a direct acknowledgement, Tesla is very involved on social media, especially CEO Elon Musk’s platform X, and the company is well aware of what is being discussed within the community.

With recent sightings of Model Y L test mules in California, peeks of the vehicle at Giga Texas, and a large call for the car to come to the U.S., Tesla is simply stoking conversation with this.

However, the company also made another move that was recognized on social media. Tesla has a large gallery that includes photos of its products so media and others can use them. This gallery applies to the U.S. market specifically, unless otherwise specified.

Tesla uploaded a Model Y L to the Gallery last night:

This seems to be another indication that the Model Y L is coming to the United States.

Musk said last year that the Model Y L could make its way to the United States late this year, but it was not something that was set in stone by Tesla. The company definitely needs to establish something in the SUV market that is larger than the Model Y, and the Model Y L might be the answer.

Even still, there are consumers out there who would love Tesla to develop something even larger, like a competitor to the Tahoe or Expedition. Tesla has not really given much of an indication that it will go in that direction.

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Tesla is using vehicle microphones to improve build quality: here’s how

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Credit: Tesla

Tesla is using the vehicles’ internal microphones to improve build quality, Vice President of Engineering Lars Moravy revealed recently.

It’s no secret that Tesla is always finding ways to make its manufacturing operations more efficient, accurate, and valuable. Constantly trying to make its cars better, the company has never placed any restrictions on what it will do to improve everything from panel gaps to paint.

As Teslas have been driving autonomously on the property of the Gigafactory Texas plant for a while now, Moravy revealed to Herbert Ong in a new interview that cars rolling off production lines now autonomously navigate themselves through a bumps, squeaks, and rattles (BSR) portion of the line. This helps to identify any loose or improperly installed internal parts.

The cabin’s microphones, which are used for a variety of things in ownership, simultaneously monitor any noises inside the vehicle while it rolls through the BSR portion of the production line. Moravy actually revealed that Tesla is trying to build “Full Self-Hearing,” an AI system that will detect minor imperfections so they can be corrected before delivery.

It’s no secret that build quality is something that Tesla struggled with as it scaled to a fully massive production operation that manufactures over 1.6 million vehicles per year. However, in recent years, especially, there have not been as many complaints. Tesla has truly improved upon its build quality and paint quality over the past several years, especially in the U.S.

Tesla’s ‘megacasts’ are key to massive build quality improvements

While those improvements have been evident, there are still some complaints; no automaker is perfect with this. But this step will now ensure that every single car that rolls off the production lines at Gigafactory Texas will be void of any creaks, squeaks, or squeals when it leaves the factory.

This measure is one of the most unique we’ve seen in terms of a strategy to avoid build quality issues, but it is not exclusive to Tesla.

Ford uses acoustic analysis AI to find abnormalities in seat motors, climate control units, and other components. Suppliers and OEMs will also use microphone arrays or particle velocity sensors in end-of-line stations.

The full interview with Lars Moravy is available below:

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Investor's Corner

Tesla crushes Wall Street expectations, beats delivery estimates by over 15 percent

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Tesla (NASDAQ: TSLA) beat Wall Street expectations of 406,000 vehicles delivered in Q2 by reporting 480,126 deliveries for the three months ending in June.

Tesla reported it delivered 467,762  Model 3 and Model Y units, while 12,364 Model S, Model X, and Cybertrucks switched hands during the quarter. The Model S and Model X were officially sunset this past quarter and will no longer be part of the company’s Production & Delivery reports moving forward.

The quarter is a pleasant surprise and a good rebound from Q1, when Tesla slightly missed the Wall Street consensus of 365,645 cars by reporting 358,023 deliveries for the first three motnhs of the year.

Energy storage deployments also provided some strength in Tesla’s delivery report, hitting 13.5 GWh for Q2. This is a particular division of Tesla’s business that has been overwhelmingly robust over the past few years, truly being a strong point of the company’s overall model.

For the year, Tesla analysts still predict deliveries to trend in the 1.69 million unit region, a modest 3 to 5 percent increase from the 1.64 million cars the company delivered last year. Tesla will likely return to more sequential and noticeable year-over-year growth as the Cybercab project starts to ramp up considerably in the next few years.

Tesla has some other potential catalysts to spur vehicle deliveries, too. Not only is it expecting Cybercab to truly start making a change in the next few years, but other vehicles could be entering the company’s lineup.

Tesla sends production Cybercab with no steering wheel, pedals to on-road testing

The slightly longer Model Y L has been a highly speculated release candidate in the U.S. It has already done incredibly well in China, and U.S. buyers have been wanting slightly more interior space than the Model Y. Now that the Model X is gone, it is more needed than ever.

Q2 highlights a pretty stable automotive division within Tesla, and no true concerns arise from these figures, especially considering it managed to beat expectations convincingly.

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