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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.

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.

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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.”

“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.

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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.

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!

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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.

Elon Musk

SpaceX to expand Central Texas facility with $8M Bastrop project

Bastrop is already the site of several Elon Musk-led ventures.

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Credit: SpaceX

SpaceX is set to expand its presence in Central Texas with an $8 million project to enlarge its Bastrop facility, as per state filings. 

The 80,000-square-foot addition, which is scheduled to begin construction on September 24 and wrap in early January 2026, was registered with the Texas Department of Licensing and Regulation and initially reported by My San Antonio

New investment

Bastrop is already the site of several Elon Musk-led ventures. The upcoming expansion will extend SpaceX’s office at 858 FM 1209, near Starlink’s operations and The Boring Company’s facilities. Just down the road, X is housed in the Hyperloop Plaza at 865 FM 1209.

SpaceX’s expansion reflects a steady buildup of resources in Bastrop since the private space firm established its presence in the area. The addition was praised by Tesla Governor Greg Abbott, who wrote on X that the expansion will “bring more jobs, innovations and will strengthen Starlink’s impact worldwide.” 

State support

In March, Gov. Greg Abbott announced a $17.3 million state grant to SpaceX for an “expansion of their semiconductor research and development (R&D) and advanced packaging facility in Bastrop.” The project is expected to create more than 400 new jobs and generate over $280 million in capital investment.

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Following the grant award, the Texas Governor also noted that SpaceX’s facility would be growing by 1 million square feet across three years to boost its Starlink program. SpaceX’s Starlink division is among the company’s fastest-growing segments, with the satellite internet system connecting over 6 million users and counting worldwide. 

Recent reports have also indicated that Starlink has struck a deal with EchoStar to acquire 50 MHz of exclusive S-band spectrum in the United States and global Mobile Satellite Service (MSS) licenses. This should pave the way for Starlink to provide 5G coverage worldwide, even in remote areas. 

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Starlink’s EchoStar spectrum deal could bring 5G coverage anywhere

The agreement strengthens Starlink’s ability to expand its mobile coverage worldwide.

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Credit: SpaceX/X

SpaceX has struck a deal with EchoStar to acquire 50 MHz of exclusive S-band spectrum in the United States and global Mobile Satellite Service (MSS) licenses, paving the way for its next-generation Starlink Direct to Cell constellation. 

The agreement strengthens Starlink’s ability to expand its mobile coverage worldwide. With the upgraded system, SpaceX aims to deliver full 5G connectivity to unmodified cell phones and eliminate mobile dead zones worldwide.

Expanding mobile coverage

Starlink’s Direct to Cell service was first launched in early 2024 with satellites designed to connect directly to standard LTE mobile devices. Within days of deployment, engineers demonstrated texting from unmodified phones, followed by video calling. Over the past 18 months, SpaceX has grown the system to more than 600 satellites, which now offer service across five continents. Today, Starlink Direct to Cell is considered the largest 4G coverage provider worldwide, connecting over 6 million users and counting, according to SpaceX in a post.

The constellation integrates with Starlink’s broader fleet of 8,000 satellites via a laser mesh network. Operating at 360 kilometers (224 miles) above Earth, the satellites connect directly to devices without hardware or firmware modifications. The system is already supporting messaging, video calls, navigation, social media apps, and IoT connectivity in remote areas.

Next-generation system

Through its new EchoStar spectrum acquisition, SpaceX plans to develop a second-generation constellation with far greater capacity. The upgraded satellites will leverage SpaceX-designed silicon and advanced phased array antennas to increase throughput by 20x per satellite and increase total system capacity by more than 100x. These enhancements are expected to support full 5G cellular connectivity in remote areas, with performance comparable to terrestrial LTE networks.

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Partnerships with major mobile carriers remain central to Starlink’s expansion. Operators including T-Mobile in the United States, Rogers in Canada, KDDI in Japan, and Kyivstar in Ukraine are integrating Direct to Cell services for coverage in rural areas and during emergencies. The service has already provided critical communication during hurricanes, floods, and wildfires, enabling millions of SMS messages and emergency alerts to be delivered when ground networks were unavailable.

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SpaceX Starship launches face pushback in Florida over noise, flights—and nudists

SpaceX is seeking permission to fly its fully reusable Starship system from Launch Complex 39A.

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Credit: SpaceX

The Federal Aviation Administration (FAA) has wrapped up a series of public hearings on SpaceX’s proposal to launch its Super Heavy Starship rocket from NASA’s Kennedy Space Center (KSC). 

The sessions, held both in-person and online, form part of the draft environmental impact statement (EIS) review that will determine whether SpaceX would be cleared to conduct Starship launches and landings from Florida’s Space Coast.

FAA review and Starship launch plans

According to the FAA’s draft EIS, SpaceX seeks permission to fly its fully reusable Starship system from Launch Complex 39A, where construction of a dedicated tower and infrastructure has already begun. Proposed operations could involve landings at KSC or droneships positioned across the Atlantic, Pacific, and Indian Oceans. The FAA emphasized that final approval is not guaranteed with the completion of the EIS, as safety and financial requirements must still be met, as noted in a Space.com report.

Starship’s larger scale compared to Falcon 9 means expanded exclusion zones for air, sea, and beach access. The analysis also projected more than 60 annual closures of Playalinda Beach, alongside potential flight delays across Florida airports lasting 40 minutes to two hours. Port Canaveral would also be affected by maritime restrictions.

Local concerns

Public comments reflected a mix of optimism and unease. Aviation officials, such as Tampa International Airport COO John Tiliacos, warned of significant disruption to commercial flights. “There is the potential that there’s going to be significant impact to commercial aviation and the traveling public. That’s something that certainly the FAA needs to give consideration to and, frankly, come up with a plan to mitigate,” he stated. 

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Others raised health concerns, noting that chronic sleep disruption from launch noise could impact veterans and trauma survivors. Robyn Memphis, a neuroscience and psychology graduate student, stated that sleep disruptions from launch noise and sonic booms could carry lasting effects. “Chronic sleep disruption is not just inconvenient. This is directly linked to depression, anxiety… cardiovascular disease, even suicide risk. And being in Florida, we have many veterans and trauma survivors in the community,” she said.

Nudist protests and responses

Erich Schuttauf, the executive director of the American Association for Nude Recreation, also argued that places like Playalinda Beach, a nudist beach, are crucial for people who travel to places where public nudity is legal. His sentiments were echoed by fellow nudist Sue Stevens, who noted that “It’s probably a quarter million people that travel and think like I do, who look for destinations that are beautiful and surrounded by like-minded people.”

Photographer Max West, who plans to move to Florida to photograph Starship, noted that the spacecraft presents a notable step forward for humanity. And while its impact to communities is not marginal, the progress it offers is well worth it. “I’m not going to say that there is zero environmental impact there,” he said, though he also stated that there has to be some “little sacrifices along the way. “The turtles and the nudists will have to migrate. That’s the cost that you have to pay for this incredible stuff that’s happening.”

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