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SpaceX completes Falcon 9 test fire, space station supply mission up next

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After almost exactly 15 months of dormancy, SpaceX’s Launch Complex 40 (LC-40) came to life with the roar of nine Merlin 1D rocket engines as Falcon 9 1035 conducted its second pre-launch static fire in preparation for the company’s 13th Commercial Resupply Services mission, CRS-13. Previously tasked with the launch of the CRS-11 Cargo Dragon, the booster completed its mission and returned safely to Landing Zone-1 (LZ-1) on June 3 2017. The path towards LC-40’s reactivation has delayed the launch approximately one week, but December 6th’s successful static fire bodes well for the current launch date, 11:46 AM on December 12.

On September 6 2016, LC-40 was effectively destroyed over the course of the Amos-6 failure. In months that followed, SpaceX reactivated LC-39A in order to continue chipping away at the company’s launch manifest, but also began the slow process of damage assessment and reconstruction of LC-40. It is safe to assume that almost every single component of the ground support equipment (GSE) was completely replaced, and interviews with Cape Canaveral’s 45th Space Wing commander suggest that SpaceX went further still, transforming the painful situation into an opportunity.

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In an exclusive and frank conversation between Brig. Gen. Wayne Monteith and Florida Today’s Emre Kelly, the commander suggested that extensive design changes and additional hardening measures implemented during reconstruction are expected to make LC-40 exceptionally resilient to the rigors of rocket launches. Most tellingly, if perhaps overly optimistic, Monteith estimated that a second vehicle failure on the order of Amos-6 might only take two months to recover from, compared to the 15 months that followed Amos-6. He attributed this claim to GSE that is now largely buried underground, theoretically protecting the vast apparatus of hand-welded piping necessary to fuel the Falcon 9 launch vehicle. The replacement Transporter/Erector/Launcher (TEL) tasked with supporting Falcon 9 during integration and launch also appears to have been modernized, and will likely end up looking quite similar to the monolithic white TEL that resides at LC-39A.

With CRS-13’s static fire now complete, the mission is set to become the fifth operational reuse of a flight-proven Falcon 9 booster in 2017, thanks to NASA’s unusually rapid acceptance of the new practice. Further still, if Iridium-4’s December 22 launch date holds, and it does look to be stable for the moment, SpaceX will rather incredibly have conducted five commercial reuses of a Falcon 9 in its first year of operations, meaning that one third of SpaceX’s 2017 missions will have launched aboard flight-proven boosters. Also impressive is SpaceX’s full-stop move towards the reuse of Cargo Dragon capsules, and the company stated over the summer that it was hoping to almost completely redirect Cargo Dragon’s manufacturing facilities towards Dragon 2, also known as Crew Dragon. This was most recently reiterated several months ago and is presumed to still be the company’s goal moving forward, and CRS-12 is believed to have been the last “new” Cargo Dragon that will fly. CRS-13’s Dragon previously flew the CRS-6 mission in April 2015.

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Photos shared privately with the author show CRS-13’s Falcon 9 to be covered in a graceful layer of soot from its previous recovery, similar in appearance to Falcon 9 1021 seen above. (Instagram/bambi_mydear)

In a December 6 tweet, SpaceX further confirmed that the deeply secretive Zuma mission, previously delayed from an early-November launch as a result of concerns about fairing defects, has now been moved from LC-39A to LC-40 and is understood to be targeting January 4 2018. This will give SpaceX approximately three weeks after the launch of CRS-13 to verify that everything is functioning nominally in what is essentially a new pad.

Meanwhile, with Zuma now officially moved to 40, LC-39A is completely free from routine operations, meaning that SpaceX’s ground crew can now work at will to ready the pad for the inaugural launch of Falcon Heavy, now aiming for early 2018. Aside from Falcon Heavy, recent FCC filings point to two additional SpaceX launches aiming for January, although slips are probable in light of CRS-13’s minor delays. Regardless, December and January are likely to be thrilling months for followers of the intrepid space exploration outfit.

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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Tesla just told us twice that Model Y L is coming to the U.S.

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Credit: Tesla

Tesla just told us twice that the Model Y L is coming to the U.S., and two social media posts definitely just tipped the company’s hand, as if they wanted it to be any other way.

The two social media posts basically confirm that the slightly longer version of the Model Y will be heading to the United States soon, and many have speculated that the company could launch the vehicle as soon as this weekend.

The first post was directly from Tesla, and it showed an incredibly long Dachshund, with words above that said, “Looking forward to the long weekend.”

Anyone who knows Tesla knows the company loves to troll its fans and have fun, and this is a perfect example of that. While not a direct acknowledgement, Tesla is very involved on social media, especially CEO Elon Musk’s platform X, and the company is well aware of what is being discussed within the community.

With recent sightings of Model Y L test mules in California, peeks of the vehicle at Giga Texas, and a large call for the car to come to the U.S., Tesla is simply stoking conversation with this.

However, the company also made another move that was recognized on social media. Tesla has a large gallery that includes photos of its products so media and others can use them. This gallery applies to the U.S. market specifically, unless otherwise specified.

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Tesla uploaded a Model Y L to the Gallery last night:

This seems to be another indication that the Model Y L is coming to the United States.

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Musk said last year that the Model Y L could make its way to the United States late this year, but it was not something that was set in stone by Tesla. The company definitely needs to establish something in the SUV market that is larger than the Model Y, and the Model Y L might be the answer.

Even still, there are consumers out there who would love Tesla to develop something even larger, like a competitor to the Tahoe or Expedition. Tesla has not really given much of an indication that it will go in that direction.

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Tesla is using vehicle microphones to improve build quality: here’s how

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Credit: Tesla

Tesla is using the vehicles’ internal microphones to improve build quality, Vice President of Engineering Lars Moravy revealed recently.

It’s no secret that Tesla is always finding ways to make its manufacturing operations more efficient, accurate, and valuable. Constantly trying to make its cars better, the company has never placed any restrictions on what it will do to improve everything from panel gaps to paint.

As Teslas have been driving autonomously on the property of the Gigafactory Texas plant for a while now, Moravy revealed to Herbert Ong in a new interview that cars rolling off production lines now autonomously navigate themselves through a bumps, squeaks, and rattles (BSR) portion of the line. This helps to identify any loose or improperly installed internal parts.

The cabin’s microphones, which are used for a variety of things in ownership, simultaneously monitor any noises inside the vehicle while it rolls through the BSR portion of the production line. Moravy actually revealed that Tesla is trying to build “Full Self-Hearing,” an AI system that will detect minor imperfections so they can be corrected before delivery.

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It’s no secret that build quality is something that Tesla struggled with as it scaled to a fully massive production operation that manufactures over 1.6 million vehicles per year. However, in recent years, especially, there have not been as many complaints. Tesla has truly improved upon its build quality and paint quality over the past several years, especially in the U.S.

Tesla’s ‘megacasts’ are key to massive build quality improvements

While those improvements have been evident, there are still some complaints; no automaker is perfect with this. But this step will now ensure that every single car that rolls off the production lines at Gigafactory Texas will be void of any creaks, squeaks, or squeals when it leaves the factory.

This measure is one of the most unique we’ve seen in terms of a strategy to avoid build quality issues, but it is not exclusive to Tesla.

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Ford uses acoustic analysis AI to find abnormalities in seat motors, climate control units, and other components. Suppliers and OEMs will also use microphone arrays or particle velocity sensors in end-of-line stations.

The full interview with Lars Moravy is available below:

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Investor's Corner

Tesla crushes Wall Street expectations, beats delivery estimates by over 15 percent

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Tesla (NASDAQ: TSLA) beat Wall Street expectations of 406,000 vehicles delivered in Q2 by reporting 480,126 deliveries for the three months ending in June.

Tesla reported it delivered 467,762  Model 3 and Model Y units, while 12,364 Model S, Model X, and Cybertrucks switched hands during the quarter. The Model S and Model X were officially sunset this past quarter and will no longer be part of the company’s Production & Delivery reports moving forward.

The quarter is a pleasant surprise and a good rebound from Q1, when Tesla slightly missed the Wall Street consensus of 365,645 cars by reporting 358,023 deliveries for the first three motnhs of the year.

Energy storage deployments also provided some strength in Tesla’s delivery report, hitting 13.5 GWh for Q2. This is a particular division of Tesla’s business that has been overwhelmingly robust over the past few years, truly being a strong point of the company’s overall model.

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For the year, Tesla analysts still predict deliveries to trend in the 1.69 million unit region, a modest 3 to 5 percent increase from the 1.64 million cars the company delivered last year. Tesla will likely return to more sequential and noticeable year-over-year growth as the Cybercab project starts to ramp up considerably in the next few years.

Tesla has some other potential catalysts to spur vehicle deliveries, too. Not only is it expecting Cybercab to truly start making a change in the next few years, but other vehicles could be entering the company’s lineup.

Tesla sends production Cybercab with no steering wheel, pedals to on-road testing

The slightly longer Model Y L has been a highly speculated release candidate in the U.S. It has already done incredibly well in China, and U.S. buyers have been wanting slightly more interior space than the Model Y. Now that the Model X is gone, it is more needed than ever.

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Q2 highlights a pretty stable automotive division within Tesla, and no true concerns arise from these figures, especially considering it managed to beat expectations convincingly.

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