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SpaceX’s Crew Dragon spacecraft nears launch debut as Falcon 9 tests wrap up

DM-1's rocket booster, Falcon 9 B1051, is nearly done with acceptance testing in Texas. (SpaceX)

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Known as Demonstration Mission 1 (DM-1), the inaugural flight of SpaceX’s Crew Dragon spacecraft is closer than ever before as the company wraps up ground testing of the rocket that will launch it.

Meanwhile, astronauts Doug Hurley and Bob Behnken are continuing to prepare for DM-2 – the first launch of Crew Dragon with crew onboard – by familiarizing themselves with SpaceX’s completed hardware, software, and procedures.

Originally expected to occur before the end of 2017, Commercial Crew partners SpaceX, Boeing, and NASA have been forced to repeatedly delay the inaugural uncrewed and crewed launches of both the Crew Dragon (SpaceX) and Starliner (Boeing) crew transport vehicles, which have slipped roughly 3-6 months with every quarterly schedule update.

Generally speaking, the sources of those delays can be split evenly between NASA and its two commercial partners. A majority of the commercial-side slips can be attributed to unexpected hardware failures between the beginning of the Commercial Crew Program (CCP) and expected launch dates, with SpaceX experiencing two catastrophic failures of Falcon 9 (CRS-7 and Amos-6) and Boeing suffering a major anomaly while performing ground tests ahead of a Starliner pad-abort. Prior to the September 2016 Amos-6 failure of Falcon 9, SpaceX was arguably on track for the inaugural launch of Crew Dragon in late-2017/early-2018, having already completed a successful pad-abort demonstration in 2015 and eight successful launches since the CRS-7 failure.

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The Statue and the Hare

Aside from serious hardware failures, the rest of SpaceX’s Commercial Crew delays can be blamed on the company’s tendency to relentlessly iterate, improve, and generally modify both its hardware and software, to the extent that SpaceX’s Vice President of Production stated in mid-2018 that “[SpaceX has] never built any two vehicles identically”. For NASA’s often dysfunctionally and counterproductively risk-averse human spaceflight divisions, that sentence alone is probably enough to trigger panic attacks. As a result, SpaceX has been led to significantly change its style of operations over the last several years, reaching some sort of compromise that was more acceptable to NASA.

Further, despite the failures of CRS-7 and Amos-6, SpaceX continued to dramatically modify Falcon 9’s design – a major vehicle-wide upgrade known as Falcon 9 1.2 (Full Thrust, Block 1) debuted on the CRS-7 return-to-flight, while Amos-6 would have been the first launch of Falcon 9 Block 3 and likely failed as a result of faster fueling procedures and much colder propellant. Less than a year later, SpaceX debuted Falcon 9 Block 4. Roughly half a year after that, SpaceX debuted Falcon 9 Block 5, perhaps the most significant upgrade to the rocket yet. Ultimately, all changes made to Falcon 9 and Crew Dragon translate into additional work for NASA and SpaceX, known formally as “certification” and informally as exhaustive testing sandwiched by mountains of paperwork.

 

In the case of the CCP, NASA itself has been a major source of delays as Boeing and SpaceX get much closer to launch dates and hardware is effectively completed, integrated, and ready to go. According to both Hans Koenigsmann (VP of Flight Reliability) and Gwynne Shotwell (President and COO) in the last few months, both executives were supremely confident that the hardware (Crew Dragon: capsule, trunk; Falcon 9: Merlins, upper stage, booster; Launch Complex 39A) would be ready for DM-1 no later than December 2018. Those statements imply that additional delays were unlikely to be a consequence of hardware readiness, indicating that delays beyond December would presumably be caused by paperwork and/or ISS scheduling.

In this sense, it could well be the case that NASA’s behind-schedule completion of critical certification and approval paperwork – paperwork that NASA alone required and knew it would have to finish prior to launch for the last several years – will or already have delayed SpaceX’s first Crew Dragon launch by at least a month. DM-1 is currently targeting a launch in January 2019.


For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet check out our brand new LaunchPad and LandingZone newsletters!

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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

Tesla Roadster’s new patent preps white-knuckle speeds, keeping it grounded

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Credit: @BLKMDL3/Twitter

Ahead of its highly anticipated unveiling, Tesla’s upcoming Roadster received a new patent that aims to keep it grounded while enabling white-knuckle speeds.

The patent, which was granted on September 29, is titled “Electric Car Fan,” bluntly stating its design but not its purpose, which is further detailed in the text of the application. Interestingly, it comes two weeks before the Roadster event, which was delayed due to unfavorable weather on Thursday, which could cause issues, as Tesla revealed the event must be held outdoors.

The purpose is to solve a problem that is relatively unique to high-performance electric cars. Instant motor torque is useless if the tires cannot plant that force, and conventional wings and underbody tunnels generate downforce only when air is already rushing past the car. At launch, in slow corners, and under hard braking from modest speed, passive aerodynamic additions contribute essentially very little to downforce.

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Tesla’s filing says that its fans can produce the downforce needed, independent of vehicle velocity, then ease off so the same hardware does not pile on drag at highway speeds, an issue that can come from excessive body modifications.

The hardware outlined in the patent is a ducted-fan package that is placed into the rear of the vehicle. An underbody inlet between the rear wheels feeds a duct that rises to a wide outlet in the diffuser. In that outlet are four axial fans, which are divided by vertical strakes. They will pull air from under the floor and press the chassis onto the pavement.

The language in the patent claims it can cut drag rather than add to it while simultaneously increasing downforce.

Tesla Roadster event requires restricted airspace, and the FAA obliges

The fans run from the high-voltage battery and a vehicle control system, so output can be modulated rather than left on as a fixed penalty.

There are additional strengths that can come from this design, like extra tire load at low speed, which can contribute to even more face-melting acceleration rates, decrease stopping distance, and sharper turn-in before a wing has air to work with. Adjustable fan speed lets the car add grip only when needed, so it can be catered to the force of a turn or acceleration.

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These designs were previously used, and banned, in some competitive settings. The Brabham BT46B was banned in F1 competition for using a similar fan design and being labeled as too effective.

Tesla still lists the Roadster as having a sub-two-second 0-60 MPH time and a 250-plus-MPH top speed, and there are expectations for a SpaceX cold-gas thruster package that could not only increase acceleration but potentially cause the vehicle to hover.

It is important to note that a patent is not a production part, and packaging four fans in a rear diffuser, managing noise, and potential debris are all things Tesla must consider. With that being said, the patent being granted shows Tesla is designing the Roadster to go fast, but it is also attempting to use unique strategies to combat any issues it might have at those speeds.

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SpaceX turned a heralding moment for Starship into its greatest

Starship reached orbit despite losing an engine, deployed 26 Starlink V3 satellites on Flight 14.

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SpaceX’s Starship reached orbit for the first time on Monday, and for a few nail-biting minutes it looked like it wouldn’t. During ascent on Flight 14, one of Ship 41’s six Raptor engines shut down early, and SpaceX’s livestream host Dan Huot told viewers the team had decided not to commit to orbit. Minutes later, after what Huot described as a lot of conversation in the control room, the final poll came back in favor, and a roughly 19 second burn of a single Raptor pushed the ship into orbit about 170 miles up.

The reversal matters because SpaceX had written the exit ramp into the mission plan. The company said it would only fire the orbital insertion burn if flight controllers confirmed enough backup hardware remained for the deorbit burn, a condition Teslarati laid out ahead of the flight. Losing an engine was exactly the scenario that rule was built for.

Pressing forward fits Elon Musk’s history. Falcon 1 failed three straight times before its fourth launch reached orbit in 2008, with SpaceX nearly out of money, and Starship was developed by flying prototypes until they broke. What changed this year SpaceX going public, and with $SPCX sliding below its IPO price in July when Flight 13 slipped, the short interest climbed significantly, as Teslarati reported at the time. A Starship potentially lost today with revenue generating next-gen Starlink satellites aboard would have landed directly on shareholders.

That pressure showed up after orbit. SpaceX cut a flight planned to last nearly 10 hours to about three, moving splashdown from west of Chile to the North Pacific near Hawaii. SpaceX gave no reason, though Musk said this month the company was being extremely cautious about debris risk. The single Raptor for deorbit worked, and Ship 41 completed its flip and landing burn before breaking apart in the water, an outcome SpaceX expected. Musk has structured SpaceX’s governance to shield long term bets from market pressure.

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The payload is the bigger business story. Musk posted that all 26 Starlink V3 satellites deployed and are “operating nominally.” Each V3 is rated for about 1 Tbps of downlink and 160 Gbps of uplink, so this single launch adds roughly 26 Tbps, about 10 times what a Falcon 9 load of V2 Mini satellites adds. The V3 is too large for Falcon 9, making Starship the only vehicle that can build out the planned 100,000 satellite constellation, at up to 60 per flight once it reaches routine service. Unlike the 20 V3 units on Flight 13, which reentered on a suborbital path, these will raise their orbits and could begin serving customers within weeks and bring in hundreds of millions of additional dollars in projected Starlink revenue.

SpaceX has already begun winding down Falcon 9 Starlink launches from Florida in favor of Starship. Reported targets put Flight 15 as early as October 19, leaving about three weeks to diagnose Monday’s engine shutdown before the next orbital attempt.

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Elon Musk

SpaceX just got the green light Starship has waited years for

The FAA has cleared Starship Flight 14, setting up SpaceX’s first orbital attempt on Monday.

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SpaceX has cleared the last regulatory hurdle standing between Starship and its first trip to orbit. The Federal Aviation Administration issued the launch license for Starship Flight 14 late Saturday, keeping the mission on track for liftoff Monday, September 28, from Pad 2 at Starbase, Texas.

The 75 minute launch window opens at 7:15 a.m. Central, and Boca Chica Beach closures are also scheduled for September 29 and 30 as backup dates. This will be Starship’s first revenue generating mission.

The license was the missing piece after SpaceX completed a full wet dress rehearsal with Booster 21 and Ship 41 on September 24. At the time, the company said the flight remained on track pending regulatory approval. Because Flight 14 flies an orbital profile, the FAA had to sign off on a modified license that met its safety, payload and financial responsibility requirements.

Observers combing through the new FAA paperwork also noticed that lightning no longer appears among Starship’s listed launch hazards. If that holds, it matters more for where Starship is headed than for Monday’s attempt. Florida and Louisiana, home to LC-39A and the planned Starbase Louisiana site, see some of the most frequent lightning in the United States.

SpaceX tells the FCC that Starship Flight 14 is going to orbit

Flight 14 is the mission SpaceX has been building toward for months. Ship 41 will carry 26 Starlink V3 satellites, the first operational V3 units to be deployed, and attempt roughly six orbits at about 275 kilometers over a flight lasting just under 10 hours. SpaceX says the ship will only perform its orbital insertion burn after flight controllers confirm enough hardware redundancy remains for the deorbit burn at the end of the mission. Ship 41 is targeting a splashdown in the Pacific west of Chile, while Super Heavy will return to the Gulf of Mexico.

The date carries some symbolism as well. A Monday launch would come 10 years and one day after Elon Musk first presented the Interplanetary Transport System, the design that became Starship, at the International Astronautical Congress in Guadalajara, Mexico.

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SpaceX has not announced what comes next, but air traffic planning slides reported this week, list Flight 15 no earlier than October 19 and a first Starship launch from LC-39A in Florida no earlier than October 30. Both dates depend on how Monday goes.

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