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SpaceX Falcon 9 Block 5 booster preps for next launch as fairing fragments surface

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As part of a recent 10-year anniversary celebration of SpaceX’s first successful launch to reach orbit, Falcon 9 B1047 was spotted undergoing inspections and refurbishment after the Block 5 booster’s launch debut, placing the 7-ton Telstar 19V communications satellite in orbit on July 22nd.

Meanwhile, a bit north of B1047’s cozy Cape Canaveral refurbishment hangar, battered fragments of a Falcon 9 payload fairing half – part of the very same Telstar 19V mission – were discovered by a fisherman off the coast of South Carolina.

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A tale of two halves

Around nine minutes after lifting off from SpaceX’s LC-40 pad, Falcon 9 B1047 gracefully landed on drone ship Of Course I Still Love You (OCISLY), followed soon after by confirmation of Falcon 9 Block 5’s second launch success. Perhaps a tad toasty after what one might call a ‘medium-well’ reentry, the upgraded booster was otherwise perfectly intact. A minute after B1047 separated from Falcon 9’s upper stage and Telstar 19V payload, the fairing – tasked with protecting the satellite from the stresses of high-speed atmospheric flight – was jettisoned from the second stage, splitting into two halves and falling away from the rocket in order to save precious mass on S2’s push towards orbit.

Falcon 9’s first stage separates from the upper stage for quite different reasons, cued quite literally by its propellant tanks essentially reaching “empty” – albeit an “empty” that typically includes some fumes for the booster’s safe recovery. The payload fairing, on the other hand, is detached from the second stage the moment that Falcon rises above a particular point in Earth’s atmosphere, only exposing its sensitive satellite(s) to the elements once in near-vacuum conditions. Ultimately, fairing halves separate from Falcon 9 at velocities significantly higher than that of the booster but are subjected to far more forgiving reentry conditions, requiring just a minimal of thermal protection to make it to (or just above…) the ground/ocean unscathed.

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SpaceX recently began seriously attempting to recover Falcon 9 payload fairings, albeit almost exclusively during West Coast launches in order to let Mr. Steven attempt to catch the parasailing halves in the Pacific Ocean. Thus far, SpaceX engineers and technicians have not yet solved the challenging problems, although fairing halves have reportedly landed as few as 50 meters from Mr. Steven’s grasp and at least five have been recovered intact after landing gently on the ocean surface. On the East Coast, Falcon fairings are not nearly as lucky, typically alternating between smashing directly into the ocean and landing gently upon it, depending SpaceX’s need for experimental recovery data.

By all appearances, B1047’s fairing halves both plummeted – unarrested – into the Atlantic, shattering into pieces of fragile carbon fiber-aluminum honeycomb. Thanks to the extremely lightweight nature of their composition, even waterlogged fairing fragments tend to float almost indefinitely, winding up in far-flung places many hundreds or thousands of miles from the point of impact. A particularly large fairing fragment from Telstar 19V clearly survived its greater halve’s violent ends, floating its way 600-800 miles northwest to the coast of South Carolina. After taking photos, the fisherman rather poetically let it float away, permitting it several more weeks of freedom before washing up on some shoreline and making its way onto eBay.

 

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Ultimately, SpaceX engineers and technicians will continue to work towards successful, reliable, and routine fairing recoveries, inevitably experiencing many failures before a functional solution is found and optimized, just like the teams that brought Falcon 9 first stage recovery from blueprint to reality. In the meantime, serendipitous events like this will continue to serve as both stark reminders of the unforgiving hurdles along the path to orbital-class rocket hardware recovery and the undeniable fact that it already can and has been done before.

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: Self-sustaining city on Mars is plausible in 25-30 years

Musk noted that true self-sufficiency requires Mars to develop “all the ingredients of civilization.”

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Credit: Elon Musk/X

Elon Musk has stated that a self-sustaining human settlement on Mars could be established in 25-30 years, provided launch capacity increases dramatically in the coming decades. 

Speaking at the All-In Summit, the SpaceX CEO said building a self-sufficient colony depends on exponential growth in “tonnage to Mars” with each launch window, highlighting Starship’s role as the company’s pathway to interplanetary initiatives.

Mars settlement goals

Musk noted that true self-sufficiency requires Mars to develop “all the ingredients of civilization,” from food production to microchip manufacturing. Starship Version 3 is expected to support the first uncrewed Mars test flights, while future iterations could reach 466 feet in height and deliver larger payloads critical for settlement. Ultimately, Musk stated that an aggressive timeline for a city on Mars could be as short as 30 years, as noted in a Space.com report.

“I think it can be done in 30 years, provided there’s an exponential increase in the tonnage to Mars with each successive Mars transfer window, which is every two years. Every two years, the planets align and you can transfer to Mars. 

“I think in roughly 15, but maybe as few as 10, but 10-15-ish Mars transfer windows. If you’re seeing exponential increases in the tonnage to Mars with each Mars transfer window, then it should be possible to make Mars self-sustaining in about call it roughly 25 years,” Musk said. 

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Starship’s role

Starship has flown in a fully stacked configuration ten times, most recently in August when it completed its first payload deployment in orbit. The next flight will close out the Version 2 program before transitioning to Starship Version 3, featuring Raptor 3 engines and a redesigned structure capable of lifting over 100 tons to orbit.

While SpaceX has demonstrated Super Heavy booster reuse, Ship reusability remains in development. Musk noted that the heat shield is still the biggest technical hurdle, as no orbital vehicle has yet achieved rapid, full reuse.

“For full reusability of the Ship, there’s still a lot of work that remains on the heat shield. No one’s ever made a fully reusable orbital heat shield. The shuttle heat shield had to go through nine months of repair after every flight,” he said. 

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SpaceX is partnering with chipmakers to enable Starlink satellite-to-cell service

President Gwynne Shotwell outlined the effort during a space industry conference in Paris.

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Credit: SpaceX/X

SpaceX is working with microchip manufacturers to integrate satellite-connectivity hardware into smartphones, advancing its plan for direct-to-device services through Starlink. 

The move follows the company’s $17 billion acquisition of wireless spectrum from EchoStar Corp., a deal that positions SpaceX to operate more independently of traditional telecom carriers. 

President Gwynne Shotwell outlined the effort during a space industry conference in Paris this week, as noted in a Bloomberg News report.

Starlink direct-to-device

Starlink currently serves millions of customers in over 100 countries, primarily through ground-based dishes. The company, however, is now expanding into satellite-to-cell service, which should enable unmodified phones to connect directly with orbiting satellites. While SpaceX has a partnership with T-Mobile US, the EchoStar spectrum purchase gives it more control to negotiate with global carriers on its own terms.

“We’re working with chip manufacturers to get the proper chips in phones,” the SpaceX President stated. “We will now be initiating discussions with telcos in a different way now. Now it’s our spectrum, but we want to work with them, almost providing capacity and wholesaling capacity to their customers.”

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The company plans to launch satellites capable of supporting its direct-to-device business within two years, with early mobile phone testing expected by late 2026.

Starship program continues test flights

Shotwell also addressed SpaceX’s Starship program, which recently completed its 10th test flight in August. She said the mission met all objectives, providing a critical morale boost to teams after a challenging development year. 

“My Starship team needed that win,” Shotwell noted. “Development programs always are kind of a 24/7 operation, and I was really pleased for them.”

SpaceX is planning to fly one more iteration of the current Starship prototype, known as V2, before transitioning to the next-generation V3 vehicle. That version, expected to debut late this year or early 2026, is designed to be more capable and support eventual crewed missions to the Moon and Mars. 

“The V3, which we want to fly hopefully late this year, but maybe early next year, is really the vehicle that could take humans to the moon and Mars,” Shotwell stated.

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U.S. Judge dismisses lawsuit against SpaceX Starship Boca Chica launch site

The ruling found that the FAA had met its obligations in reviewing the potential environmental effects of Starship launches.

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(Credit: SpaceX)

A U.S. district court judge has dismissed a lawsuit brought by conservation groups challenging the Federal Aviation Administration’s approval of SpaceX’s expanded rocket launch operations in Boca Chica, Texas. 

The ruling, issued Monday, found that the FAA had met its obligations in reviewing the potential environmental effects of Starship launches.

FAA review withstands legal challenge

The lawsuit centered on whether the FAA properly assessed the impact of SpaceX’s operations on endangered wildlife, including ocelots, jaguarundis, and Kemp’s Ridley sea turtles, as noted in a report from The Guardian. The plaintiffs argued that noise, light pollution, and construction activity degraded the surrounding habitat, which also serves as nesting grounds for threatened shorebirds.

The lawsuit cited SpaceX’s April 2023 Starship test, which destroyed its launchpad and scattered debris across a large area. The blast reportedly ignited a grassfire and damaged wildlife habitats, including a bobwhite quail nest.

Judge Carl Nichols, for his part, ruled that the FAA had satisfied its obligation“to take a hard look at the effects of light on nearby wildlife.” The decision effectively cleared a regulatory hurdle for SpaceX, which has been working to expand Starship launch activity at its Boca Chica facility.

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A continued ramp

SpaceX continues to scale its operations nationwide. Beyond Starship, the company is also seeking approval to nearly double Falcon rocket launches from Vandenberg Space Force Base in California, from 50 annually to 95. 

Former President Trump has also shared his intention to increase U.S. launch capacity, setting a target for substantial growth by 2030. Considering that SpaceX is by far the world’s dominant launch provider, Trump’s support for more launches will likely benefit the private space company.

For now, at least, the ruling should allow continued expansion at a time when Starship remains central to long-term goals such as Mars missions and NASA’s Artemis program.

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