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SpaceX prepares for space station supply mission as secret Zuma launch postponed

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Zuma patiently awaits a new launch date

Just shy of two weeks ago, SpaceX announced the discovery of unspecified problems with a Falcon 9 payload fairing during routine quality assurance (QA) testing at the company’s Hawthorne, CA factory. The launch of Zuma, a deeply mysterious satellite with no clear manufacturer or customer, was subsequently delayed indefinitely, pending the results of an internal investigation into the aforementioned fairing defects.

Several days after SpaceX’s Zuma announcement, the Falcon 9 booster, second stage, and payload (often referred to as the “stack”) were rolled back into the pad facilities at LC-39A, verifying that a delay of at least several days would follow. This delay was both confirmed and denied in a confusing manner, with the Cape’s 45th Space Wing appearing to suggest that Zuma would not be impacted by a preplanned range closure in late November, although journalist Irene Klotz reported that Zuma was delayed until December, when maintenance was scheduled to end.

SpaceX’s mysterious Zuma payload and Falcon 9 1043 seen before stormy Florida skies. (Tom Cross/Teslarati)

All things considered, the month of November has been an unusually chaotic period for SpaceX and the Space Coast, and the chaos has almost certainly been exacerbated by the intense secrecy surrounding Zuma. As the sum total of publicly available information, these details indicate that SpaceX employees discovered a systemic defect or defects in recently-manufactured fairings, serious enough to indefinitely ground the company’s commercial launches. However, SpaceX recently opened press registration for the Iridium-4 mission, still apparently scheduled for launch on December 22 and further corroborated by the CEO of Iridium Communications, hinting that that mission’s fairing either predates the scope of the fairing investigation, or that the investigation and fairing groundings have arisen out of an abundance of caution above all else.

A Dragon stretches its wings

More importantly and perhaps more logically, SpaceX’s next Cargo Dragon mission to the International Space Station – CRS-13 – has not been directly impacted by fairing problems; Dragon missions do not require fairings. The CRS-13 mission, currently aiming for a static fire on November 29 and launch on December 4, will be exceptional for a number of equally thrilling reasons. In no particular order: CRS-13 will mark the first NASA-approved reuse of a Falcon 9’s first stage, in this case with the added aesthetic bonus that the Dragon will reach orbit aboard the same booster that launched CRS-11’s Dragon almost exactly six months prior, June 3 2017. Equally exciting, CRS-12 marked the final new Cargo Dragon launch, and CRS-13’s Dragon is a refurbished spacecraft, having previously flown the CRS-6 mission in late 2015.

 

Rather poetically, CRS-11 marked the first commercial reuse of an orbital spacecraft, and the booster that launched that mission, Falcon 9 1035, will now fly once more to lift the second-ever reused Dragon into orbit. If all goes as planned, SpaceX’s CRS-13 mission will arguably be the most-reused orbital-class mission in the history of spaceflight, with only the second stage and Dragon’s trunk being both new and expendable. Both the booster and Dragon likely required a fair amount of refurbishment, but if Elon Musk’s June 2017 statements remain accurate, SpaceX has probably progressed far along the reusability learning curve. Quoting Elon Musk and myself at the ISS R&D Conference in July 2017:

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Musk said he expects the next Dragon reuse and all future reuses to save the SpaceX nearly 50% of the cost of manufacturing an entirely new spacecraft. Musk admitted that the first refurbishment of Dragon likely ended up costing as much or more than a new vehicle, but this is to be expected for the first attempt to reuse any sort of space hardware that must survive some form of reentry heating and saltwater immersion.

Indeed, CRS-13 will in fact be “the next Dragon reuse” after CRS-11’s success. If the spacecraft’s refurbishment does manage save SpaceX anywhere near 50% of the cost of manufacture, the mission will be an extraordinary accomplishment, above and beyond the already intense difficulty of refurbishing and reflying a several-ton (~4000kg empty) orbital spacecraft.

LC-40 pad repairs near completion

Even after the reuse of both the Dragon and Falcon 9 booster, CRS-13 will lay host to yet another milestone for SpaceX as the first mission to launch from the newly repaired Launch Complex-40 (LC-40), after the pad suffered widespread damage from a Falcon 9 failure during preparations for the launch of Amos-6. Little is known on the specifics of the damage suffered, but repairs have taken no less than 14 months and at a minimum required the fabrication, assembly, and qualification of entirely new Ground Support Equipment (GSE).

 

Under the umbrella of GSE are thousands of feet of precisely machined and welded piping and pumps, a new launch mount and transporter-erector-launcher (TEL) to carry Falcon 9 out of the integration facilities, the repair or complete removal and replacement of a huge volume of scalded concrete, and the repair or replacement of likely dozens or hundreds of other miscellaneous components destroyed in the intense fire that followed the Amos-6 incident. Nevertheless, as spotted on a social media platform by the author, the aforementioned TEL and launch mount were shown going vertical just a handful of days ago, further evidence that LC-40 is once again rapidly marching towards operational status.

The long-awaited reactivation and return to operations at LC-40 is itself arguably the most critical path ahead of Falcon Heavy’s inaugural launch, and modifications to the pad and TEL have restarted in light of Zuma’s indefinite delays, with SpaceX’s ever-productive and heroic ground crew taking advantage of extra down-time between launches. With Zuma now ~11 days past its scheduled launch date, the mission’s delay will likely result in additional delays to Falcon Heavy’s inaugural launch, which was reported to be aiming for ~December 29. This deep of a delay might also necessitate the transfer of Zuma’s launch from LC-39A to LC-40, depending on the customer’s flexibility and SpaceX’s own needs. Time will tell, and in the meantime, the mystery of Zuma and wondrous accomplishments of CRS-13 ought to sate the launch withdrawals of SpaceX fans for the time being.

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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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USDOT Secretary visits Tesla Giga Texas, hints at national autonomous vehicle standards

The Transportation Secretary also toured the factory’s production lines and spoke with CEO Elon Musk.

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Credit: Elon Musk/X

United States Department of Transportation (USDOT) Secretary Sean Duffy recently visited Tesla’s Gigafactory Texas complex, where he toured the factory’s production lines and spoke with CEO Elon Musk. In a video posted following his Giga Texas visit, Duffy noted that he believes there should be a national standard for autonomous vehicles in the United States.

Duffy’s Giga Texas Visit

As could be seen in videos of his Giga Texas visit, the Transportation Secretary seemed to appreciate the work Tesla has been doing to put the United States in the forefront of innovation. “Tesla is one of the many companies helping our country reach new heights. USDOT will be right there all the way to make sure Americans stay safe,” Duffy wrote in a post on X. 

He also praised Tesla for its autonomous vehicle program, highlighting that “We need American companies to keep innovating so we can outcompete the rest of the world.”

National Standard

While speaking with Tesla CEO Elon Musk, the Transportation Secretary stated that other autonomous ride-hailing companies have been lobbying for a national standard for self-driving cars. Musk shared the sentiment, stating that “It’d be wonderful for the United States to have a national set of rules for autonomous driving as opposed to 50 independent sets of rules on a state-by-state rules basis.”

Duffy agreed with the CEO’s point, stating that, “You can’t have 50 different rules for 50 different states. You need one standard.” He also noted that the Transportation Department has asked autonomous vehicle companies to submit data. By doing so, the USDOT could develop a standard for the entire United States, allowing self-driving cars to operate in a manner that is natural and safe.

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Tesla posts Optimus’ most impressive video demonstration yet

The humanoid robot was able to complete all the tasks through a single neural network.

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Credit: Tesla Optimus/X

When Elon Musk spoke with CNBC’s David Faber in an interview at Giga Texas, he reiterated the idea that Optimus will be one of Tesla’s biggest products. Seemingly to highlight the CEO’s point, the official Tesla Optimus account on social media platform X shared what could very well be the most impressive demonstration of the humanoid robot’s capabilities to date.

Optimus’ Newest Demonstration

In its recent video demonstration, the Tesla Optimus team featured the humanoid robot performing a variety of tasks. These include household chores such as throwing the trash, using a broom and a vacuum cleaner, tearing a paper towel, stirring a pot of food, opening a cabinet, and closing a curtain, among others. The video also featured Optimus picking up a Model X fore link and placing it on a dolly.

What was most notable in the Tesla Optimus team’s demonstration was the fact that the humanoid robot was able to complete all the tasks through a single neural network. The robot’s actions were also learned directly from Optimus being fed data from first-person videos of humans performing similar tasks. This system should pave the way for Optimus to learn and refine new skills quickly and reliably.

Tesla VP for Optimus Shares Insight

In a follow-up post on X, Tesla Vice President of Optimus (Tesla Bot) Milan Kovac stated that one of the team’s goals is to have Optimus learn straight from internet videos of humans performing tasks, including footage captured in third person or by random cameras.

“We recently had a significant breakthrough along that journey, and can now transfer a big chunk of the learning directly from human videos to the bots (1st person views for now). This allows us to bootstrap new tasks much faster compared to teleoperated bot data alone (heavier operationally).

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“Many new skills are emerging through this process, are called for via natural language (voice/text), and are run by a single neural network on the bot (multi-tasking). Next: expand to 3rd person video transfer (aka random internet), and push reliability via self-play (RL) in the real-, and/or synthetic- (sim / world models) world,” Kovac wrote in his post on X.

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Starship Flight 9 nears as SpaceX’s Starbase becomes a Texan City

SpaceX’s launch site is officially incorporated as Starbase, TX. Starship Flight 9 could launch on May 27, 2025. 

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(Credit: Jenny Hautmann/Wikimedia Commons)

SpaceX’s Starbase is officially incorporated as a city in Texas, aligning with preparations for Starship Flight 9. The newly formed city in Cameron County serves as the heart of SpaceX’s Starship program.

Starbase City spans 1.5 square miles, encompassing SpaceX’s launch facility and company-owned land. A near-unanimous vote by residents, who were mostly SpaceX employees, led to its incorporation. SpaceX’s Vice President of Test and Launch, Bobby Peden, was elected mayor of Starbase. The new Texas city also has two SpaceX employees as commissioners. All Starbase officials will serve two-year terms unless extended to four by voters.

As the new city takes shape, SpaceX is preparing for the Starship Flight 9 launch, which is tentatively scheduled for May 27, 2025, at 6:30 PM CDT from Starbase, Texas.

SpaceX secured Federal Aviation Administration (FAA) approval for up to 25 annual Starship and Super Heavy launches from the site. However, the FAA emphasized that “there are other licensing requirements still to be completed,” including policy, safety, and environmental reviews.

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On May 15, the FAA noted SpaceX updated its launch license for Flight 9, but added: “SpaceX may not launch until the FAA either closes the Starship Flight 8 mishap investigation or makes a return to flight determination. The FAA is reviewing the mishap report SpaceX submitted on May 14.”

Proposed Texas legislation could empower Starbase officials to close local highways and restrict Boca Chica Beach access during launches. Cameron County Judge Eddie Trevino, Jr., opposes the Texas legislation, insisting beach access remain under county control. This tension highlights the balance between SpaceX’s ambitions and local interests.

Starbase’s incorporation strengthens SpaceX’s operational base as it gears up for Starship Flight 9, a critical step in its mission to revolutionize space travel. With growing infrastructure and regulatory hurdles in focus, Starbase is poised to become a cornerstone of SpaceX’s vision, blending community development with cutting-edge aerospace innovation.

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