Connect with us

News

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)

Published

on

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.

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.

Check out Teslarati’s Marketplace! We offer Tesla accessories, including for the Tesla Cybertruck and Tesla Model 3.

Advertisement
-

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.

Advertisement
Comments

News

Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says

Published

on

Credit: United Airlines

United Airlines CEO Scott Kirby said that SpaceX’s Starlink satellite internet is its leading competitive advantage in the U.S. airline industry. However, in recent comments, while he described the service as “the biggest competitive advantage” the carrier currently holds, he also acknowledged that the edge is temporary.

“…everybody eventually is going to have high-speed low earth orbit internet connectivity. It’s going to be a must-have. We are going to have a few years of being the only airline that has it at scale, and that’s our mission,” Kirby said. Until everyone has it, United aims to capitalize on its head start by converting trial users into long-term loyal customers.

United has moved faster than its rivals on Starlink installations. As of mid-to-late October 2026, the system was on roughly 43 percent of its fleet, with plans to reach 61 percent by year-end, 87 percent by June 2027, and full fleet coverage by the end of next year.

The airline already operates more Starlink-equipped flights than the rest of the U.S. industry combined. Los Angeles International Airport is scheduled to become United’s first 100 percent Starlink hub in the first half of 2027, and the carrier’s app will display the likelihood that any given flight has the service.

Kirby has pointed to early evidence that the offering influences booking decisions. Some passengers loyal to other airlines are already switching flights for Starlink connectivity, something the airline, along with American Airlines, has tried to leverage against competing airlines. Both companies used status-match programs, and some of those customers are pursuing company-specific credit cards, which signals an intent to stay.

Once onboard, these customers encounter the airline’s broader investments in aircraft, larger seat-back screens, oversized bins, connection tools, and a mobile app that Kirby says outperforms competitors. Wi-Fi satisfaction scores on Starlink-equipped planes have been reported to be nearly double those on aircraft with other systems.

Competitors are moving slowly to do the same. Southwest Airlines began installations in 2025 and expects to complete them soon. Delta is pursuing Amazon’s Leo system, while American expects to start Starlink work in early 2027 and has not yet detailed regional-fleet plans. This timeline gap gives United a multi-year window in which it remains the only major U.S. carrier offering Starlink at scale.

Kirby has framed the strategy as pressing that advantage while simultaneously widening gaps in other technology areas so that customers who try United for the Wi-Fi remain for the overall experience.

The approach reflects a calculated bet that superior in-flight connectivity can accelerate share gains and support longer-term financial targets, including a 10 percent pre-tax margin goal.

High-speed internet is particularly valued by premium and business travelers who can work or stream reliably. As low-Earth-orbit service becomes ubiquitous, the temporary nature of the pure connectivity edge means United’s retention will depend on whether its other product and operational improvements keep pace.

Continue Reading

News

Tesla Cybercab’s unorthodox paint process explained

Published

on

Credit: Tesla

Tesla Cybercab skips the traditional paint shop entirely, marking an unorthodox process for coloring the fully autonomous vehicle. However, the decision was a smart one, as it slashed factory costs, floor space utilization, and complexity, since Tesla relied on specialized alloys and in-mold coloring.

Munro Live was given the opportunity to do a factory walkthrough with Tesla Vice President of Vehicle Engineering Lars Moravy, who explained and detailed how Cybercab production at Giga Texas eliminates one of the automotive manufacturing industry’s most expensive and space-hungry elements.

A conventional paint line can cost hundreds of millions of dollars and require a million man-hours to build. Moravy framed the choice around Tesla’s core rule: “Question the requirements: why do you need paint?”

The structural answer lies in material selection. The aluminum alloys used in Cybercab’s front and rear castings do not oxidize and lose strength over time, the way many common automotive aluminum alloys do. Only the side modules, built around hot-stamped boron-steel door rings, receive an anti-corrosion e-coat, or dip coat. Front and rear modules skip coating altogether.

Model Y and Model 3 bodies, by contrast, are fully coated and painted.

Exterior colors come from the plastics shop, which Tesla engineers described as “our paint shop” for the Cybercab. Body panels are produced via reaction injection molding, referred to as RIM. Color is then mixed into a polyurethane resin at the mix head immediately before injection, so the panel emerges already colored with a Class-A surface.

Robots trim overflow to control sink marks and flow lines. The process avoids conventional spray-paint defects like orange peel and paint bleed. Scratches can still be repaired with compatible coatings that behave “basically like paint.” Because color is integral rather than a surface layer, shallow scratches do not expose a contrasting undercoat.

The secret behind Tesla’s Cybercab Gold goes well beyond just the color

Tesla has also explored related approaches, including in-mold lamination and painted films on stamped panels.

The manufacturing payoff is substantial because removing the paint shop, combined with the “unboxed” modular process that builds and tests front, rear, side, and center modules in parallel before a short final assembly, cuts factory floor space per vehicle by about 50 percent.

Final assembly itself uses only about 25 automated stations, far fewer than the typical Model Y line, and the overall line runs at about 78 percent automation, Moravy said. The approach also eliminates volatile organic compound emissions associated with traditional spray painting for these panels and shortens the coloring cycle from hours to minutes.

Cybercab’s paint strategy is clearly less about aesthetics than about systematically deleting capital-intensive, energy-heavy, and space-consuming steps once material science and process design make them unnecessary. It is a concrete example of Tesla applying first-principles questioning to one of the auto industry’s most entrenched factory requirements.

Continue Reading

Investor's Corner

Tesla has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

Published

on

By

Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

Advertisement
-

The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

Continue Reading