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SpaceX restores a Falcon 1 rocket for 10th anniversary of first launch success

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With plans to give the historic rocket its own place on display inside the company’s Hawthorne factory, SpaceX has refurbished the last remaining Falcon 1 rocket booster and an old Merlin 1C engine to create a model representative of the same Falcon 1 that saved SpaceX and made history on September 28th, 2008, becoming the first privately-developed liquid-fuel rocket to reach Earth orbit.

In the process of celebrating the tenth anniversary of that crowning achievement, one is reminded just how meteoric SpaceX’s rise has been over the course of that decade, marked by relentless progress with Falcon 1, Falcon 9, Falcon Heavy, Cargo Dragon, Crew Dragon, and even the early phases of BFR construction.

https://twitter.com/SpaceXJobs/status/1045832573471969281

On that September afternoon ten years ago, SpaceX may well have saved itself from extinction. Running on funding fumes, CEO and founder Elon Musk has long held that the company would have been forced to effectively cease activity and disband after six years of work and three consecutive Falcon 1 failures had drained almost all of the $100 million he had dedicated in 2002.

Reaching orbit is undoubtedly one of the most technologically challenging feats there is and SpaceX’s merciless failures drove that reality home, ranging from a burst propellant line on the first stage Merlin, liquid propellant sloshing problems on the second stage, and overperformance on the first stage engine causing the two stages to impact after separation, among myriad other problems faced outside of actual launch attempts. Thankfully, thanks to the extraordinary group of several hundred early employees that fixed those problems and pushed onwards, Falcon 1’s fourth attempt was almost flawless and successfully placed a boilerplate mass simulator into a roughly circular ~650km orbit.

 

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A bit more than nine months later, SpaceX completed the first and last operational launch of Falcon 1, retired to allow the company to focus fully on Falcon 5 (cancelled a few years later), Falcon 9, and Cargo Dragon. Eleven months after that July 2009 mission, SpaceX successfully launched Falcon 9 for the first time and followed it up with the first launch of a functioning Cargo Dragon spacecraft, which spent several hours testing systems in orbit before reentering Earth’s atmosphere and landing in the Pacific Ocean. Two years later in 2012, SpaceX’s Cargo Dragon became the first commercial spacecraft in history to dock with the International Space Station, with operational NASA Commercial Resupply Services launches beginning just six months after.

Falcon 1’s 5th and final flight, July 2009. (SpaceX)

With three years and five successful launches under its belt, Falcon 9 v1.0 was retired and made way for the first of many upgraded Falcon 9 variants, known as Falcon 9 v1.1, featuring 60% greater thrust and mass at liftoff, a new octaweb layout for its nine new Merlin 1D engines, and a range of structural changes that set the stage for future attempts at booster recovery. Two and a half years after Falcon 9 v1.1’s debut and a little over five years since the first successful launch of Falcon 1, SpaceX accomplished the first successful landing of a Falcon 9’s first stage, and that booster now stands proudly outside of the company’s Hawthorne, CA headquarters.

To mark that 10th anniversary, SpaceX apparently decided to salvage a mothballed Falcon 1 stored in a junkyard, refurbishing it into something closer to its former self. Although just the first stage and a Merlin 1C engine were present, the company stationed the refurbished Falcon 1 in front the first recovered Falcon 9 booster and gave all employees an opportunity to see the duo over the course of September 28th.

 

The sheer size differential is undeniably impressive. However, a more gobsmacking statistic can be found still. Falcon 1 stands roughly 22 meters tall and would weigh around 39,000 kilograms with a full load of liquid oxygen and kerosene. While the Falcon family’s current payload fairing isn’t nearly tall enough to squeeze in a full Falcon 1 first stage, Falcon Heavy could easily place a fully-loaded Falcon 1 into Low Earth Orbit and still recovery all three of its first stage boosters.

In other words, SpaceX went from launching the first commercial liquid-fuel rocket to reach orbit to launching a super-heavy rocket that could put that entire first rocket into orbit in less than ten years. Not too shabby.


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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SpaceX readies Starship Flight 14 for a historic journey into uncharted territory

SpaceX finished Starship’s Flight 14 rehearsal, clearing the way for its first orbital flight Monday.

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Sunrise at Starbase. Starship is stacked for opportunistic full-stack testing ahead of Flight 14 via SpaceX
Sunrise at Starbase. Starship is stacked for opportunistic full-stack testing ahead of Flight 14 via SpaceX

SpaceX has cleared one of the last hurdles before Starship’s first trip to orbit. The company posted on X Thursday afternoon that its launch rehearsal for Flight 14 was complete, keeping the mission on track for Monday, September 28. The launch window opens at 7:15 a.m. CT at Starbase, Texas, and runs for 75 minutes.

A wet dress rehearsal is essentially launch day without the launch. Crews fill Booster 21 and Ship 41 with thousands of tons of extremely cold propellant, run the countdown nearly to ignition, then drain everything back out. It lets engineers catch leaks or equipment problems before anything leaves the pad. SpaceX still needs a launch license from the FAA before the stack, which stands 407 feet tall, can fly.

Flight 14 matters because of where it is going. All 13 previous Starship flights followed a suborbital path, which works like throwing a ball extremely high and far: the vehicle reaches space, but it is always on a course that brings it back down within about an hour. This time, Ship 41 will perform a short engine firing called an orbital insertion burn roughly 25 minutes after liftoff, giving it enough speed to keep falling around Earth instead of back into it. SpaceX plans about six laps at an altitude near 275 kilometers (171 miles) over nearly 10 hours, as Teslarati detailed when the mission was first announced.


Getting into orbit also means Starship has to prove it can get back out. The ship must relight a single Raptor engine in space to slow down for reentry. SpaceX says it will only attempt the orbital insertion burn after flight controllers confirm the hardware needed for that return burn has enough backup, and its flight plan includes health checks that could shorten the mission to two or five orbits.

Flight 14 is also the first to put working satellites into service. Flight 13 carried 20 Starlink V3 satellites in July, but they came back down with the ship because that mission never reached orbit. This time, 26 V3 satellites are meant to stay up and join the constellation within a few weeks. Together they add about 26 terabits per second of network capacity, which SpaceX says is roughly 10 times what a single Falcon 9 launch of older V2 Mini satellites adds. Three of them carry cameras that will photograph Starship’s heat shield in orbit to check for tile damage before reentry.

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The hardware has changed too. Ship 41 flies with extra fasteners on tiles in the most vulnerable areas, fixes for gaps where superheated plasma slipped behind tiles, and curved tiles designed to reduce heating between them. Two tiles recovered from Ship 40 will fly again, the first reuse of any part of a Starship heat shield. Booster 21 carries better engine filtering and new relight software after ice clogged three center engines on the previous booster, leaving only eight of 13 engines to restart for its landing burn.

Ship 41 is targeting a splashdown in the Pacific Ocean west of Chile, a new recovery zone after several Indian Ocean landings, while Booster 21 aims for the Gulf. Neither will be caught by the tower on this flight. Elon Musk said in August that a ship catch was likely “in a few months.”

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Google just picked SpaceX for its first step into orbital AI

Google will launch its first Project Suncatcher AI satellite on SpaceX’s Transporter-18 rideshare next week.

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Google is about to put its own AI chips into orbit for the first time, and it is paying SpaceX to get them there.

The company said Thursday that the first in-orbit test of Project Suncatcher, its research effort to find out whether space can host large-scale AI computing, will fly next week on SpaceX’s Transporter-18 rideshare mission.

The satellite, called MVP, is about the size of a refrigerator and carries four of Google’s Tensor Processing Units, the same chips Google runs in its ground data centers. Google originally planned to launch two custom satellites in 2027, but chose to move faster by integrating its chips into a satellite.

MVP’s solar panels supply about one kilowatt of power, and Google will run Gemini models on the TPUs only in bursts of roughly 15 minutes before the chips shut down so the radiators can shed heat. In a blog post, Google said its Trillium TPUs survived vibration testing that mimicked sustained launch loads of up to 10g, with individual components seeing 50 to 100g, and handled a radiation dose greater than a five year mission would deliver.

SpaceX and Google mull massive partnership on Musk’s orbital data dream: report

Next week’s flight, slated for October 1, follows a relationship that became public in May, when Teslarati reported that Google was in talks with SpaceX for a launch deal tied to orbital data centers. Google also holds a stake of roughly 6% in SpaceX.

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The two companies are chasing the same idea from very different starting points. SpaceX’s own orbital compute program is built around the AI1 satellite, a roughly 70 meter structure derived from Starlink V3 hardware that is designed for 150 kW of peak compute, about 150 times the power MVP will draw. Elon Musk has brushed off concerns about crowding orbit with those satellites, and SpaceX is building its Gigasat factory in Bastrop, Texas, to produce them, targeting an annualized rate of about 1 GW of space compute by the end of 2027.

Musk also posted on X on Thursday that “the amount of compute in space will obviously round up to 100% of all compute.”

Google has been more cautious in public. Its research estimates that launch prices need to fall below about $200 per kilogram before an orbital data center can compete with a ground facility on energy cost, a threshold the company believes could be reached around the mid 2030s. The Suncatcher team has said it expects the effort to remain a project rather than a product for years, which leaves the first real test of its hardware riding on a rocket from the company with the most aggressive timeline in the field.

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Tesla Cybercab gets initial tie-in to localized, in-house cathode plant

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Credit: Tesla

Tesla has taken another concrete step toward owning its battery supply chain, and it’s doing so with what is perhaps the most important vehicle in its short-but-storied history.

On September 23, Tesla announced that it has officially built the first Cybercab with cathode material produced in-house at the company’s first cathode plant in the U.S., and the first in the U.S. overall.

Active cathode material is the most expensive piece of a lithium-ion battery cell, and it often accounts for more than a third of cell cost. For years, the industry sourced a majority of it from Asia, but Tesla’s decision to make it in the United States bodes well for the Cybercab project. This is the latest chapter in Tesla’s vertical integration strategy, which began in public at Battery Day in 2020.

At the Battery Day Event, Elon Musk said the company would build a North American cathode plant and overhaul the process to cut costs and waste, while also making some of the most powerful and long-lasting cells in the industry.

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The Austin facility took years to appear. Tesla filed permits for “Project Cathode” in 2022 on land near Giga Texas. By mid-2022, the building frame was up and Tesla later invested hundreds of millions of dollars as part of a larger expansion of the Giga Texas plant. The company stated it was operating the first large-scale cathode production facility in North America to supplement 4680 cell production.

One month later, that material reached a finished Cybercab.

The timing of this breakthrough is monumental for the Cybercab program. As Tesla officially launched the first Cybercab rides to the public earlier this month, production of the ride-hailing-geared vehicle is moving forward on the planned S-curve that CEO Elon Musk told everyone to expect.

Nevertheless, packs of Cybercab units have been spotted throughout the United States, in an effort to potentially activate the fleet as soon as the company gains regulatory approval in various geographic areas.

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On top of that, Tesla owning the cathode step and pairing it with its own in-house lithium from the Gulf Coast refinery shortens the supply chain that once stretched thousands of miles and subjects every pack to fewer external price shocks and geopolitical risks.

Tesla is not yet independent of all of its foreign suppliers, as some precursor metals come from mines and chemical plants. But the first in-house cathode Cybercab shows the company is closing the most expensive and most concentrated gap in its battery production efforts. For a vehicle like Cybercab to operate at a high utilization within the Robotaxi network, that control over cost is so crucial.

It is arguably as important as the software that drives it.

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