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SpaceX loses record-breaking rocket booster after sixth successful Starlink launch

Minutes after breaking SpaceX's reusability record, Falcon 9 booster B1048 was lost shortly before attempting a drone ship landing. (Richard Angle)

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SpaceX has suffered its second rocket landing failure of 2020 despite the fact that both lost Falcon 9 boosters successfully launched 60 Starlink satellites, an anomaly that CEO Elon Musk says will need a “thorough investigation”.

After a rare last-second launch abort on March 15th and a three-day range-related delay, Falcon 9 booster B1048 lifted off with 60 upgraded Starlink v1.0 satellites on its fifth orbital-class mission. At least for the first two and half minutes, the booster performed precisely as intended, carrying a fueled upper stage and its ~16 metric ton (36,000 lb) payload to an altitude of 55 km (34 mi) and a velocity of 1.8 km/s (1.1 mi/s). However, about 10 seconds before the booster reached main engine cut-off (MECO) and stage separation, something went wrong.

While there is some ambiguity in his response, according to Musk, at least one of Falcon 9 B1048’s nine Merlin 1D engines performed an early shutdown before MECO. The rocket’s computer immediately accounted for the anomaly, extending the remaining eight-engine booster burn 5-7 seconds beyond the nominal timeline to ensure mission success. While the booster’s loss is still disappointing and the premature engine shutdown more than a little concerning, it’s critical to remember that mission success was ensured. Just 15 minutes after liftoff, the rocket’s upper stage successfully spun up and deployed another 60 Starlink satellites, bringing SpaceX’s operational constellation to an incredible ~350 satellites.

B1048 punches through Max Q on what would turn out to be the Falcon 9 booster’s swan song. (Richard Angle)
Minutes after breaking SpaceX’s reusability record, Falcon 9 booster B1048 was lost for unknown reasons shortly before attempting a drone ship landing. (SpaceX)
Despite the booster anomaly, SpaceX has now successfully launched 360 Starlink satellites. (SpaceX)

Based on live views available from SpaceX’s launch webcast, it appears that Falcon 9’s “early engine shutdown” is more of a euphemism for a fairly violent engine failure that triggered an instantaneous cutoff, preventing damage elsewhere. While SpaceX would certainly rather avoid in-flight engine failures, Falcon 9’s nine Merlin 1D booster engines are installed inside an aluminum ‘octaweb’ structure that transmits their thrust to the rest of the rocket but also effectively quarantines each engine in a blast-proof bunker.

Despite the partial failure, Falcon 9 B1048 continued to fight its way through its landing trajectory until it either ran out of propellant or burnt up during reentry. (SpaceX)

Nevertheless, the rocket’s highly-attuned software and affected octaweb engine bunker did their jobs, instantly shutting the failing engine down while also preventing the explosion and resulting shrapnel from damaging the rest of the rocket. More likely than not, B1048’s autonomous decision to always put mission success before booster recovery lead the booster to expend a majority of the propellant needed for its landing attempt to make up for the 10 or so seconds operating at only ~89% thrust.

As a result, B1048 may have simultaneous subjected itself to a much more extreme atmospheric reentry and run out of propellant before it could complete (or maybe even start) its drone ship landing burn. There’s also a chance that the engine that failed was one of the three engines required for reentry and landing burns, an asymmetry that would be impossible to overcome on the fly. Ultimately, the booster likely impacted the ocean at a near-supersonic velocity, smashing it into aluminum confetti. Thankfully, the late B1048 had a record-breakingly productive career as an orbital-class booster, placing dozens of tons of payload into orbit over five successful launches. Its loss is regrettable but the booster has more than earned its keep.

Aside from two twice-flown Falcon Heavy Block 5 side boosters of unknown status and 2-3 new boosters assigned to critical NASA and US Air Force missions, SpaceX’s fleet is now down to just three flightworthy Falcon 9 boosters. This could dramatically limit its options for near-term commercial flights, as none of those rockets – even assuming flawless launch and landing debuts – will likely be ready for their first reuses until May or June. Meanwhile, B1051 and B1049 have three and four missions under their respective belt and both completed their last launches just 50-70 days ago, while B1059 flew for the second time just two weeks ago. Despite the fact that it successfully completed its fifth mission, B1048’s in-flight engine failure will almost certainly delay upcoming launches, although the degree of those delays is up for debate.

Up next for SpaceX is SAOCOM 1B, an Argentinian radar satellite set to become the first payload launched into a polar orbit from the US East Coast in half a century. Before B1048’s anomaly, the mission was scheduled to launch no earlier than March 30th and could use any of unassigned boosters described above

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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’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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Investor's Corner

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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