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Merlin 1D's kerolox exhaust is a blindingly bright, opaque yellow-orange. (Tom Cross) Merlin 1D's kerolox exhaust is a blindingly bright, opaque yellow-orange. (Tom Cross)

SpaceX

SpaceX to launch replacement satellite two years after fateful Falcon 9 failure

Falcon 9 B1049 lifts off from SpaceX's LC-40 launch pad on September 10. (Tom Cross)

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On September 1st, 2016, SpaceX’s Falcon 9 rocket suffered a catastrophic anomaly during a static fire test, causing an explosion that completely destroyed the vehicle, the launch pad, and Spacecom’s $200M Amos-6 satellite. This ultimately triggered a months-long investigation into what CEO Elon Musk described as “the most difficult and complex failure [SpaceX has] had in 14 years.”

More than two years and 41 successful consecutive launches later, SpaceX and Israeli satellite operator Spacecom are reportedly aiming to launch Amos-6’s replacement – Amos-17 – as early as the end of May, around three months from now.

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Nearly two and a half years distant, the reverberations of SpaceX’s Amos-6 Falcon 9 failure continue to reverberate loudly. Aside from demanding changes to the operational procedures used to launch Falcon 9 and forcing an extensive critical analysis of design, production, and qualification methods, SpaceX has spent countless resources pursuing an extensive redesign of the component pointed at as the primary source of the explosion that destroyed Falcon 9. Known as composite overwrapped pressure vessels (COPVs), SpaceX uses the bottles to store extremely high-pressure helium (5000+ psi, 340+ bar) to pressurize Falcon 9’s RP-1 and oxygen tanks, as well as nitrogen to power its cold-gas maneuvering thrusters.

According to a failure analysis performed by SpaceX with NASA, the USAF, the NTSB, and the FAA, it was concluded that the cause could be traced back to a complex series of events centered around those helium COPVs. Meant to be the first mission to utilize subcooled propellant and oxidizer, the extreme cold in the upper stage LOx tank caused solid oxygen to form on the outside of the COPVs located inside it. While complex, the gist was that liquid (and perhaps solid) oxygen could have formed around the outside of the COPV, potentially finding its way in between the carbon fiber wrappings, creating a buckle in the fibers, and ultimately causing fibers to break. Near the end of this process, those breaking fibers could have created a spark or breached the helium tank, instantaneously overpressurizing the upper stage and causing an explosion.

NASA’s Aerospace Safety Advisory Panel (ASAP) and NASA itself have aired concerns about those COPVs since 2016, triggering an extraordinarily comprehensive program of testing, characterization, and redesign of the COPVs SpaceX uses. They have now successfully flown on 3-4 Falcon 9 launches under the same expedited propellant loading conditions that an identical rocket will undergo in preparation for Crew Dragon launches. CEO Elon Musk spent several minutes discussing the redesigned COPVs in a May 2018 press conference and did not mince words when he described them as “by far the most advanced pressure vessel[s] ever developed by humanity.”

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“The amount of testing and research that’s gone into COPV safety is gigantic. This is by far the most advanced pressure vessel ever developed by humanity. It’s nuts. And I’ve personally gone over the test design, I’ve lost count how many times. But the top engineering minds at SpaceX have agonized over this. We’ve tested the living daylights out of it. We’ve been in deep, deep discussions with NASA about this. And I think we’re in a good situation.” – SpaceX CEO Elon Musk, May 2018

NASA and ASAP concerns have since been alleviated, culminating on February 22nd with an official announcement that NASA was ready for SpaceX to conduct the first uncrewed launch of its Crew Dragon spacecraft on March 2nd. It’s thus almost poetic that customer Spacecom chose the same week to announce a target date for the Falcon 9 launch of a satellite built to replace the destroyed Amos-6, known as Amos-17. Soon after the Amos-6 disaster, Spacecom settled on a free SpaceX launch contract for a future satellite instead of an immediate $50M payout. Procured for around $160M, SpaceX is reportedly targeting the launch of the Boeing-built satellite during the week of May 27th, likely from Launch Complex 40 (LC-40) – the same pad that suffered extensive damage during the September 2016 anomaly.

 

Since Amos-6, SpaceX’s record of reliability has been effectively spotless and now stands at an impressive 41 consecutive successful launches, including Falcon Heavy’s February 2018 debut. Aside from the sheer volume of launches SpaceX performed in a little over two years, the company has pushed full speed ahead towards its goal of routinely reusing Falcon 9 boosters. Less than 24 months after the first commercial reuse, SpaceX has landed Falcon 9 boosters 34 times and reused them 20 times, numbers that are only likely to grow in 2019.

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Set to occur shortly after the planned launch debuts of Crew Dragon and Falcon Heavy (commercially), SpaceX will hopefully be able to place Amos-17 in a healthy orbit and thus effectively retire the Amos-6 saga before the second half of 2019.


Check out Teslarati’s newsletters for prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket launch and recovery processes!

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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SpaceX’s Starship V3 is almost ready and it will change space travel forever

SpaceX is targeting April for the debut test launch of Starship V3 “Version 3”

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SpaceX is closing in on one of the most anticipated rocket launches in history, as the company readies for a planned April test launch and debut of its next-gen Starship V3 “Version 3”.

The latest iteration of Starship V3 has a slightly taller Super Heavy booster and Starship upper stage than their predecessors, and produce stronger, more efficient thrust using SpaceX’s upgraded Raptor 3 engines. V3 also features increased propellant capacity, targeting a total payload capacity of over 100 tons to low Earth orbit, compared to around 35 tons for its predecessor. With Musk’s lifelong aspiration to colonize Mars one day, the increased payload capacity matters enormously, because Mars missions require moving massive amounts of cargo, fuel, and eventually, people. But the most critical upgrade may be orbital refueling. SpaceX’s entire deep space architecture depends on moving large amounts of propellant in space, and having orbital refueling capabilities turn Starship from just a rocket into a true transport system. Without it, neither the Moon nor Mars is reachable at scale.

A fully reusable Starship and Super Heavy, SpaceX aims to drive marginal launch costs down and at a tenfold reduction compared to current market leaders. To put that in perspective, getting a kilogram of cargo to orbit today costs thousands of dollars. Bring that number down far enough and space stops being an exclusive domain. That price point unlocks mass deployment of satellite constellations, large-scale science payloads, and affordable human transport beyond Earth orbit. It also means the Moon stops being a destination we visit and starts being one we inhabit.

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Elon Musk pivots SpaceX plans to Moon base before Mars

NASA expects Starship to take off for the Moon’s South Pole in 2028, with the ultimate goal of establishing a permanently crewed science station there. A successful V3 flight this spring keeps that timeline alive.  As for Mars, Musk has shifted focus toward building a self-sustaining city on the Moon first, arguing that the Moon can be reached every 10 days versus Mars’s 26-month alignment window. Mars remains the horizon, but the Moon is the proving ground.

Elon Musk hasn’t been shy with hyping the upcoming Starship V3 launch. In a social media post on Wednesday, he confirmed the first V3 flight is getting closer to launch. SpaceX also announced its initial activation campaign for V3 and Starbase Pad 2 was complete, wrapping up several days of cryogenic fuel testing on a V3 vehicle for the first time. The countdown is on. April can’t come soon enough.

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FCC chair criticizes Amazon over opposition to SpaceX satellite plan

Carr made the remarks in a post on social media platform X.

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Credit: @SecWar/X

U.S. Federal Communications Commission (FCC) Chairman Brendan Carr criticized Amazon after the company opposed SpaceX’s proposal to launch a large satellite constellation that could function as an orbital data center network.

Carr made the remarks in a post on social media platform X.

Amazon recently urged the FCC to reject SpaceX’s application to deploy a constellation of up to 1 million low Earth orbit satellites that could serve as artificial intelligence data centers in space.

The company described the proposal as a “lofty ambition rather than a real plan,” arguing that SpaceX had not provided sufficient details about how the system would operate.

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Carr responded by pointing to Amazon’s own satellite deployment progress.

“Amazon should focus on the fact that it will fall roughly 1,000 satellites short of meeting its upcoming deployment milestone, rather than spending their time and resources filing petitions against companies that are putting thousands of satellites in orbit,” Carr wrote on X.

Amazon has declined to comment on the statement.

Amazon has been working to deploy its Project Kuiper satellite network, which is intended to compete with SpaceX’s Starlink service. The company has invested more than $10 billion in the program and has launched more than 200 satellites since April of last year.

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Amazon has also asked the FCC for a 24-month extension, until July 2028, to meet a requirement to deploy roughly 1,600 satellites by July 2026, as noted in a CNBC report.

SpaceX’s Starlink network currently has nearly 10,000 satellites in orbit and serves roughly 10 million customers. The FCC has also authorized SpaceX to deploy 7,500 additional satellites as the company continues expanding its global satellite internet network.

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NASA watchdog says Starship development delays could affect Artemis timeline

The report noted that several technical milestones still need to be completed before Starship can serve as a crewed lunar lander.

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Credit: SpaceX

A NASA watchdog report stated that continued development work on SpaceX’s Starship could affect the timeline for the agency’s planned Artemis moon missions. The report noted that several technical milestones still need to be completed before the spacecraft can serve as a crewed lunar lander.

The findings were detailed in a report from NASA’s Office of Inspector General, as noted in a report from Reuters.

NASA selected SpaceX’s Starship in 2021 to serve as the Human Landing System (HLS) for its Artemis lunar program. The vehicle is intended to transport astronauts from lunar orbit to the surface of the Moon and back as part of future Artemis missions.

According to the watchdog report, Starship’s development has experienced roughly two years of schedule delays compared to earlier expectations. Still, NASA is targeting 2028 for the first crewed lunar landing using the Starship lander.

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One of the most significant technical milestones for Starship’s lunar missions is in-space refueling.

To support a crewed lunar landing, multiple Starship launches will be required to deliver propellant to orbit. Tanker versions of Starship will transfer fuel to a storage depot spacecraft, which will then refuel the lunar lander.

The report noted that this approach could require more than 10 Starship launches to fully refuel the spacecraft needed for a single lunar landing mission.

NASA officials indicated that demonstrating cryogenic propellant transfer in orbit remains one of the most important technical steps before Starship can be certified for lunar missions.

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SpaceX has conducted 11 Starship test flights since 2023 as the company continues developing the fully reusable launch system. A 12th test flight, this time featuring Starship V3, is expected to be held in early April. 

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