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SpaceX prepares for last launch until August: Caution over cadence

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After a second automatic T-10s launch abort Monday night, Elon Musk expressed a welcome prioritization of caution over an attempt to break cadence records. As such, the launch team at LC-39A are standing down an attempt today and instead conducting a full review of the Falcon 9 vehicle and ground systems, pushing the launch to either July 5th or 6th. As Musk transparently phrased it, there is only one chance to get a rocket launch right.

Following a truly unprecedented series of launches for the company, there was understandably a bit of annoyance from fans watching the coverage for a second time, as well as from journalists seeking to cover the launch. I think a tweet from former NASA Space Shuttle Program Manager Wayne Hale summed up the proper response most coherently, however, stating that “it’s tough to remain vigilant and do the right thing, extremely tough after a couple of launch scrubs and [with] range closure looming”. Remaining vigilant is precisely what SpaceX is doing by calling off another attempt on July 4th and choosing to instead carefully examine the systems involved to ensure that there is no real issue with pad or vehicle hardware.

For launch companies, there are an untold number of external and internal pressures urging executives to attempt launches, be those financial, political, or something as simple as employees wanting to get home for a holiday. However, past failures of launch vehicles, particularly the Space Shuttle, have demonstrated that constant vigilance is a necessity when dealing with rocketry. Wayne Hale was flight director for forty Shuttle launches. In fact, he became Program Manager the day of the Columbia disaster, which occurred at the beginning of February in 2003.

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In this context, his statement is almost certainly intended as positive – albeit solemn – encouragement for the choice to take a more cautious route before attempting another launch. SpaceX itself has experienced two widely publicized failures of the Falcon 9, with the most recent of those having occurred less than ten months ago. After China suffered a complex failure during the second launch of their Long March 5 heavy lift vehicle last Sunday, Musk offered sympathy for those involved. Any failure in the launch industry often acts as a wake-up call for other companies and agencies involved, and undoubtedly becomes a reminder that one cannot become too comfortable or allow launch processes or vehicle manufacturing to become too routine when the stakes are as high as they can be.

It goes without saying that SpaceX is sharply aware of the need to ensure reliability and safety as they march ever closer to the debut flight of Crew Dragon and its first crewed launches, likely to occur in early 2018. If the stakes for launching the payloads of commercial customers are already high, the price of failures that could lead to loss of life are unspeakable and ought to humble those fans and bystanders who may be losing patience while waiting for a third (admittedly enthralling) launch. Those eager to watch SpaceX’s live coverage must seek to remember that the launches we love to watch occur because paying customers have placed trust in SpaceX to deliver their payloads to orbit, be those payloads massive geostationary communications satellites or astronauts and cargo headed to the ISS. Rightfully so, the customer will always come first, and routine live coverage of rocket launches must always be treated as the luxury it is for the indefinite future.

SpaceX has successfully recovery and reused both Falcon 9 and Cargo Dragon in the last several weeks, and has also recovered three first stages from the three related launches that occurred in that same time period. (SpaceX)

Admittedly, a cornerstone of SpaceX’s mission as a company is making access to orbit reliable, affordable, and routine, but there will always be risk in rocket launches, just as there will always be risk when one boards a plane, drives a car, or simply walks down the sidewalk along a busy street. Minimizing and reducing the risk present in spaceflight will take a considerable amount of time and effort, and doing what is necessary to prevent failures from negatively impacting the customers that make SpaceX viable as a company is both a rational and ethical strategy.

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Returning to current events, the Falcon 9 intended to launch Intelsat 35e went horizontal on July 4, and is likely now in the integration facility present at LC-39A, providing easier access to engineers as they comb over the vehicle to ensure its health. After an absolutely picturesque launch attempt Monday evening, weather is looking even better for a potential launch attempt on either Wednesday or Thursday evening.

If the vehicle and pad cooperate, Intelsat 35e will be a facing send off for the Eastern Range before it shuts down for the remainder of July to undergo routine maintenance. SpaceX currently does not have Vandenberg (West coast) missions scheduled until August, so July will likely see no launches from the company. There is still plenty to be done in lieu of launching customer payloads, however. LC-40, the pad damaged in the Amos-6 static fire incident last September, is currently preparing to be reactivated, with a recent interview of Gwynne Shotwell pointing to its initial availability sometime in August. Once it is reactivated, all single core Falcon launches will be transferred to LC-40, and LC-39A will begin undergoing structural modifications to accommodate both crewed missions in 2018 and Falcon Heavy, which could debut as early as Q4 of 2017.

The two most visible changes that will occur at LC-39A will be the installation of additional hold-down clamps and modifications to the Transporter Erector, as well as a Crew Access Arm, which will be attached to the large, vertical structure seen directly right of Falcon 9. Of note, it is very likely that at least two, if not all three of the first Falcon Heavy’s cores are already present at the Cape. After years of being deemed a paper rocket, Falcon Heavy is indeed very real and very close to being able to conduct its first launches.

A month of no launches from SpaceX will undoubtedly be less than thrilling, but the Air Force and Kennedy Space Center employees will get a much-deserved break from a busy launch manifest ahead of what will likely be an even busier final four months of the year. There is a lot to look forward to.

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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 rescue mission for stranded ISS astronauts nears end — Here’s when they’ll return home

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Credit: SpaceX

SpaceX is ready to bring home Butch Wilmore and Suni Williams, the two astronauts that have been stranded on the International Space Station (ISS) for nine months.

Last week, SpaceX launched its Crew-10 mission, which would dock onto the ISS late Saturday night and be the two astronauts’ ride home. Now, the end is in sight, and it appears both NASA and SpaceX are planning to have the two home this week, perhaps earlier than expected.

SpaceX readies to rescue astronauts from International Space Station

The agency and the company have announced that Dragon will autonomously undock from the ISS on Tuesday at 1:05 a.m. ET and should re-enter Earth’s atmosphere and splashdown off the Florida coast about 17 hours later.

SpaceX said:

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“SpaceX and NASA are targeting Tuesday, March 18 at 1:05 a.m. ET for Dragon to autonomously undock from the International Space Station. After performing a series of departure burns to move away from the space station, Dragon will conduct multiple orbit-lowering maneuvers, jettison the trunk, and re-enter Earth’s atmosphere for splashdown off the coast of Florida approximately 17 hours later the same day.”

Crew-9 astronaut Nick Hague will be alongside Williams and Wilmore on the flight home, along with Roscosmos cosmonaut Aleksandr Gorbunov. Hague and Gorbunov have been in space since Saturday, September 28.

SpaceX was tasked with bringing Wilmore and Williams home after the Boeing Starliner that sent them there was determined not to be suitable for their return.

A report from the New York Post in late August said that Boeing employees routinely made fun of SpaceX workers, only for the company to bail them out:

SpaceX bails out Boeing and employees are reportedly ‘humiliated’

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Crew-10 will bring the astronauts home, ending an extensive and unscheduled stay in space.

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SpaceX readies to rescue astronauts from International Space Station

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Credit: SpaceX

SpaceX is readying to launch the Crew-10 mission this evening, which will bring home U.S. astronauts Butch Wilmore and Suni Williams, who have been stuck on the International Space Station for nine months.

SpaceX is working alongside NASA to bring the two astronauts home, and all systems and weather conditions are looking ideal to launch the mission this evening from the Kennedy Space Center in Florida.

Boeing was originally tasked with the rescue mission.

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The company sent a Starliner aircraft to the ISS in late September in an effort to bring Williams and Wilmore home. However, malfunctioning thrusters and other issues on the Starliner aircraft prevented NASA from giving the green light to the astronauts to board and come home.

SpaceX was then tasked with bringing the two home, and it appears they will be on their way shortly.

The launch was intended to occur on Wednesday, but a last-minute problem with the rocket’s ground systems forced SpaceX and NASA to delay until at least Friday. Things are looking more ideal for a launch this evening.

The launch is targeted for 7:03 p.m. ET, but another backup opportunity is available tomorrow, March 15, at 6:41 p.m.

SpaceX writes about the Dragon spacecraft that will be used for the mission:

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“The Dragon spacecraft supporting this mission previously flew NASA’s Crew-3Crew-5, and Crew-7 missions to and from the space station. This will be the second flight for the first stage booster supporting this mission, which previously launched the SES 03b mPOWER-e mission. Following stage separation, Falcon 9’s first stage will land on Landing Zone 1 (LZ-1) at Cape Canaveral Space Force Station.”

The mission will not only aim to bring the two astronauts who have been stranded for nine months home, but it will also conduct new research to prepare for human exploration beyond low-Earth orbit.

If Crew-10 launches at the planned time this evening, it will dock to the ISS at 11:30 p.m. ET on Saturday night.

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Texas awards SpaceX $17.3M grant to expand Bastrop tech hub

The grant will be used to to expand SpaceX’s Bastrop complex, which produces Starlink terminals.

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Credit: SpaceX

Texas Governor Greg Abbott announced Wednesday that SpaceX has received a $17.3 million grant from the Texas Semiconductor Innovation Fund. The grant will be used to expand SpaceX’s Bastrop complex. 

SpaceX’s Bastrop complex is headlined by its Starlink factory, which is currently capable of producing 15,000 dishes per day, as per a video published by the private space company on social media platform X.

The Grant

The investment is expected to develop SpaceX’s semiconductor research and development (R&D) and advanced packaging facility in Bastrop. The expansion is expected to create over 400 jobs and over $280 million in capital investment, as per a press release from the Office of the Texas Governor.

Bastrop’s Planned Expansion

SpaceX plans to grow its Bastrop site by one million square feet over the next three years, focusing on Starlink kit production, including advanced silicon components. The proposed project includes printed circuit boards (PCBs), a semiconductor failure analysis lab, and advanced packaging for panel level packaging (PLP). Once complete, SpaceX’s Bastrop facility will stand as the largest PCB and PLP facility in North America.

What They Are Saying

SpaceX President Gwynne Shotwell shared her appreciation for Texas’ support, saying, “Incredible innovation and high-tech manufacturing is happening in Texas as a direct result of Governor Abbott’s leadership and the Texas Semiconductor Innovation Fund initiative. We love Texas. SpaceX is investing hundreds of millions of dollars into our Bastrop facility. This grant will help continue to expand Bastrop’s manufacturing for Starlink to help connect even more people across the state and around the world with high-speed, low-latency internet.”

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Texas Governor Abbott also shared his thoughts on the matter: “Texas connects the nation and the world with the most advanced technologies manufactured right here in our great state. I congratulate SpaceX on their more than $280 million investment in this Texas-sized expansion of their semiconductor R&D and advanced packaging facility in Bastrop, which will be the largest of its kind in North America. 

“Working together with innovative industry leaders like SpaceX, Texas will continue to rank No. 1 for semiconductor research and high-tech manufacturing and secure critical domestic supply chains as we build a stronger, more prosperous Texas than ever before,” he said.

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