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SpaceX teases extreme Falcon 9 launch cadence goals in Starship planning doc

Falcon 9 rolls out to Pad 39A in February 2019 for Crew Dragon's orbital launch debut, known as Demo-1. (NASA - Joel Kowsky)

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Published as part of an August 2019 environmental assessment (EA) draft for Starship’s prospective Pad 39A launch facilities, SpaceX revealed plans for a truly mindboggling number of annual Falcon 9 and Falcon Heavy launches by 2024.

As environmental planning documents, the figures should be taken with a large grain of salt and be treated as near-absolute ceilings rather than practical goals. Nevertheless, SpaceX revealed plans for its two Florida launch sites (LC-40 and LC-39A) to ultimately support as many as 70 annual launches of Falcon 9 and Heavy by 2024, less than five years from now.

Simply put, even the most dogmatic fan would have to balk at least a little bit at the numbers SpaceX suggested in its Starship EA draft. More specifically, SpaceX apparently has plans to support as many as 20 annual Falcon 9/Heavy launches from Pad 39A and an incredible 50 annual Falcon 9 launches from LC-40 as early as 2024.

“SpaceX plans to increase the Falcon launch frequency to 20 launches per year from LC-39A and up to 50 launches per year from LC-40 by the year 2024. However, as Starship/Super Heavy launches gradually increase to 24 launches per year, the number of launches of the Falcon would decrease.

–SpaceX, Starship Environmental Assessment Draft, August 2019

SpaceX’s massive Launch Complex 39A is pictured here. (USAF – Hope Geiger, February 2019)
Falcon 9 B1047 lifts off from SpaceX’s LC-40 pad on August 6th, 2019. (SpaceX)

Two obvious options

Given just how significant of an increase a 70-launch annual cadence would be for SpaceX relative to their current record of 21 launches, it’s entirely possible that these numbers are really just a pipe dream included in a pending environmental assessment to hedge bets just in case a similar launch frequency is achieved over the next five years.

On the other hand, it’s possible that SpaceX – just now coming into the ability to reliably achieve a much higher cadence – has coincidentally become payload-constrained at almost the same time, meaning that the company’s customers’ payloads just aren’t ready for launch. This would explain, for example, why SpaceX has only launched 10 times this year when the company had already completed 15 launches by August 2018.

SpaceX completed its 10th launch of 2019 on August 6th, placing the AMOS-17 communications satellite into a healthy orbit. (SpaceX)

Additionally, it can be almost unequivocally assumed that all but 15-20 of those supposed 70 annual launches would come from SpaceX’s own internal demand for Starlink launch capacity. Assuming no improvements between now and 2024, 50 Falcon 9 launches could place as many as 3000 Starlink satellites in orbit in a single year, equivalent to more than 25% of the entire proposed ~11,800-satellite constellation.

Barring regulatory changes to US Federal Communications Commission (FCC) and International Telecommunication Union (ITU) requirements, SpaceX must launch at least half of all Starlink satellites (~5900) by November 2024 and finish launching the remaining ~5900 by November 2027. If SpaceX fails to reach those deployment milestones, the company runs the risk of losing Starlink’s domestic and international licenses to operate.

SpaceX successfully launched an unprecedented set of 60 prototype Starlink satellites (internally nicknamed “v0.9”) in May 2019. (SpaceX)

This would help to explain why SpaceX says that it’s planning to reach a maximum cadence of 70 annual launches “by 2024”, given that 2024 will be a pivotal year in the eyes of regulations currently in effect for Starlink.

Starship confusion

As noted in the quote above, SpaceX plans to eventually phase out Falcon 9 and Heavy launches as the company’s next-generation Starship and Super Heavy launch vehicle gradually comes online, proves itself reliable, and begins operational launch activities. According to SpaceX, given just how much mass Starship can nominally launch relative to both Falcon 9 and Heavy, far fewer launches will be needed to accomplish the tasks that would otherwise require several times more launches of SpaceX’s smaller vehicles.

SpaceX’s initial Environmental Assessment for Starship launches from Pad 39A caps the rocket’s maximum cadence at 24 annual launches. Oddly, this directly contradicts the goals set for Starship (formerly BFR) by CEO Elon Musk and SpaceX more generally. By building a launch vehicle that is fully and rapidly reusable, the goal has long been to deliver cheap, aircraft-like access to orbit at a completely unprecedented scale.

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Starship was never meant to lower SpaceX’s annual launch cadence. (SpaceX)

This would technically mean that SpaceX could actually dramatically increase its launch cadence without increasing costs, allowing the company to perform currently nonsensical missions where Starship might launch payloads weighing just 5-10% of its total payload capacity. Airline operations routinely do things of a similar nature, sometimes flying just a fraction of their maximum passenger load to destinations for a variety of reasons.

Additionally, SpaceX has consistently indicated that Starship will rely heavily on orbital refueling to accomplish its ultimate deep space ambitions. Previous presentations from Elon Musk have shown that launches to the Mars or Moon with significant payload would require no fewer than five separate tanker launches and orbital refuelings, all of which would classify as one of the 24 annual launches SpaceX has described in its August 2019 EA draft. On their own, launching two Starships to Mars with 100 tons of payload each would require no fewer than 10-12 launches.

A 2017 overview of a Starship (then BFS) mission to Mars. (SpaceX)

Ultimately, it’s unwise to draw any substantial conclusions from an Environmental Assessment like the one the above information has been taken from. This 39A-specific EA also ignores the possibility of a similar launch facility being developed in Boca Chica, Texas, which SpaceX explicitly acknowledges.

This particular draft is also the first Starship-related EA ever filed by SpaceX, and the company may thus be treating it more as a bare minimum with the intention of eventually pursuing far more ambitious launch rates once Starship has been established.

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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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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.

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.

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.

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.

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.

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.

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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