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SpaceX Falcon 9 rideshare will test the tools needed to build space stations in orbit

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A SpaceX customer has announced that one of a future Falcon 9 rideshare missions will carry a technology demonstrator designed to prove that space stations can one day be built in space by cannibalizing expended rocket upper stages.

https://twitter.com/NanoRacks/status/1196465388168589315

On November 18th, commercial space company Nanoracks revealed that it had manifested its first “In-Space Outpost” mission on one of SpaceX’s recently-announced Falcon 9 rideshare missions, scheduled to launch as early as Q4 2020. Known for its successful efforts to use the International Space Station’s capabilities to affordably deploy hundreds of commercial small satellites, Nanoracks has also branched out into organizing rideshare opportunities for smallsats on much larger launches, another method of lowering costs.

Most recently, however, Nanoracks began to pursue a new venture centered around building unprecedentedly affordable human-rated space stations in Earth orbit. While not fundamentally new, Nanoracks proposed a unique solution: modify expended launch vehicle upper stages already in orbit to build space stations in-situ.

https://twitter.com/NanoRacks/status/1196479182127161345

It’s anyone’s guess whether such a concept can actually produce safe, affordable space stations and do so more effectively than the obvious alternative of designing, building, and launching already-finished space station components. Nevertheless, Nanoracks has firmly decided to attempt the feat. The technical hurdles alone will require numerous in-space demonstrations of custom hardware, and the Outpost Nanoracks has manifested on a Q4 2020 Falcon 9 rideshare mission will be the first of those attempted demonstrations.

“As a member of the Outpost program team, Maxar will develop a new articulating robotic arm with a friction milling end-effector for this mission. This friction milling will use high rotations per minute melting our metal material in such a way that a cut is made, yet we anticipate avoiding generating a single piece of orbital debris.

The mission is targeting a Q4 2020 dedicated rideshare mission, will fly on an ESPA ring, and will activate after the deployment of all other secondary payloads is complete. As our mission commences, we will have 30 minutes to one hour to complete the cutting of three metal pieces that are representative of various vehicle upper stages, including the Centaur 3. Nanoracks plans to downlink photos and videos of the friction milling and cutting.”


Nanoracks, 11/18/19

Nanoracks wants to use robot arms to cut and build space stations out of expended upper stages already in orbit. (Nanoracks)

As described above, the first Outpost test will focus on proving that the metal tanks of upper stages can be manipulated and cut in orbit with robotic arms to be built by Maxar. The experimental mission will reportedly take place while the payload is still attached to Falcon 9’s upper stage payload adaptor and will carry along three separate propellant tank coupons instead of attempted to mill and cut Falcon 9 itself.

As one of SpaceX’s proposed rideshare missions, Nanoracks will likely be just one of a few dozen other customers or spacecraft catching a ride, and the Outpost experiment will only begin after all other satellites have successfully deployed. Earlier this year, SpaceX announced that Smallsat Rideshare Program and rapidly modified it soon after, adding numerous new launch opportunities and lowering the base price to from ~$2.25M (150 kg) to $1M for 200 kg (440 lb) of spacecraft or experiments. Aside from 3-4 annual dedicated launches, SpaceX also plans to reserve some amount of space on certain Starlink launches, dozens of which are currently planned annually.

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Nanoracks’ Outpost-1 mission is expected to launch no earlier than Q4 2020.

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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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