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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)

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SpaceX static fires Falcon 9 with satellites on board for the first time in years

Falcon 9 B1049 lifts off for the first time in September 2018. The same booster has been assigned to Starlink v0.9. (Tom Cross)

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SpaceX has successfully completed a Falcon 9 static fire ahead of Starlink’s first dedicated launch, breaking a practice that dates back to Falcon 9’s last catastrophic failure to date.

That failure occurred in September 2016 around nine minutes before a planned Falcon 9 static fire test, completely destroying the rocket and the Amos-6 communications satellite payload and severely damaging Launch Complex 40 (LC-40). Since that fateful failure, all 42 subsequent Falcon 9 and Falcon Heavy satellite launches have been preceded by static fire tests without a payload fairing attached. This process typically adds 24-48 hours of work to launch operations, an admittedly tiny price to pay to reduce the chances of a rocket failure completely destroying valuable payloads. With Starlink v0.9, SpaceX is making different choices.

When supercool liquid oxygen ruptured a composite overwrapped pressure vessel (COPV) in Falcon 9’s upper stage, the resultant explosion and fire destroyed Falcon 9. Perhaps more importantly, the ~$200M Amos-6 satellite installed atop the rocket effectively ceased to exist, a loss that posed a serious threat to the livelihood of its owner, Spacecom. Posed with a question of whether saving a day or two of schedule was worth the potential destruction of customer payloads, both customers, SpaceX, and their insurers obviously concluded that static fires should be done without payloads aboard the rocket.

The only exceptions since Amos-6 are the launch debuts of Falcon Heavy – with a payload that was effectively disposable and SpaceX-built – and Crew Dragon DM-1, in which Falcon 9’s integration with Dragon’s launch abort system had to be tested as part of the static fire. Every other SpaceX rocket launch since September 2016 has excluded payloads during each routine pre-flight static fire.

Falcon Heavy ignites all 27 Merlin 1D engines for the first time ahead of its inaugural launch, January 2018. (SpaceX)
SpaceX completed a successful static fire of the first Falcon 9 rated for human flight on January 24th, 2019. (SpaceX)

SpaceX’s Spacecraft Emporium

Why the change of pace on this launch, then? The answer is simple: for the first time ever, SpaceX is both the sole payload/satellite stakeholder and launch provider, meaning that nearly all of the mission’s risk – and the consequences of failure – rest solely on SpaceX’s shoulders. In other words, SpaceX built and owns the Falcon 9 assigned to the mission, the 60 Starlink test satellites that make up its payload, and the launch complex supporting the mission.

Even then, if Falcon 9 were to fail during an internal SpaceX mission, customer launches could be seriously delayed by both the subsequent failure investigation failure and any potential damage to the launch complex. In short, although an internal mission does offer SpaceX some unique freedoms, it is still in the company’s best interest to treat the launch like any other, even if some customer-oriented corners are likely begging to be cut. Additionally, the loss of SpaceX’s first dedicated payload of 60 Starlink satellites could be a significant setback for the constellation, although it may be less significant than most would assume.

The same pad will host GovSat-1 in just over 24 hours.
A December 2017 panorama of SpaceX’s LC-40 facilities, CRS-13’s Cargo Dragon and Falcon 9. (Tom Cross/Teslarati)

This is not to say that SpaceX won’t take advantage of some of the newfound freedom permitted by Starlink launches. In fact, CEO Elon Musk has stated that one of SpaceX’s 2019 Starlink missions will become the first to reuse a Falcon fairing. Additionally, SpaceX is free to do things that customers might be opposed to but that the company’s own engineers believe to be low-risk. Notably, Starlink missions will be an almost perfect opportunity for SpaceX to flight-prove reusability milestones without having to ask customers to tread outside of their comfort zones.

The sheer scale of SpaceX proposed Starlink constellation – two phases of ~4400 and ~12,000 satellites – means that the company will need all the latent launch capacity it can get over the next 5-10 years, at least until Starship/Super Heavy is able to support internal missions. Extraordinary packing density will help to minimize the number of launches needed, but the fact remains that even an absurd 120 satellites per launch (double Starlink v0.9’s 60) would still require an average of 12 launches per year to finish Starlink before 2030.

One of the first two prototype Starlink satellites separates from Falcon 9’s upper stage in February 2018. (SpaceX)
OneWeb deployed six development satellites in February 2019, the company’s first hardware to reach orbit. (Arianespace)

In the meantime, thoughts of a dozen or more annual Starlink launches are somewhat premature. SpaceX’s first dedicated Starlink launch (deemed Starlink v0.9) is scheduled to lift off no earlier than 10:30 pm EDT (02:30 UTC), May 15th, and is being treated as an advanced but still intermediary step between the Tintin prototypes and a finalized spacecraft design. Still, in an unprecedented step, SpaceX has built sixty Starlink satellites for the development-focused mission, in stark contrast to the six satellites (still a respectable achievement) competitor OneWeb launched in February 2019 as part of its own flight-test program.

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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 shows what Roadster drivers will see on screen before thruster activation

Tesla’s Roadster video reveals a fighter jet inspired cockpit with a 5,500 PSI thruster gauge.

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The next generation Tesla Roadster’s touchscreen, shown in Tesla’s first official look at the car’s interface. (Credit: Tesla/X)

Tesla has given future owners their clearest look yet at the cockpit of its next generation Roadster. In a 34 second video posted to X on Friday afternoon, the company walked through the car’s touchscreen with a caption: “Inspired by fighter jet cockpits, Roadster’s interface was designed around the pilot.”

The clip opens on a black screen with red graphics and a 3D wireframe of the car, which sits beside the Roadster’s squared off yoke. Tapping parts of the model brings up controls for the rear wing, including low drag and high downforce positions, along with a charging page with a charge limit bar and a small music player. A row of tabs along the bottom reads Home, Vehicle, Listen, Climate and Navigate.

Most of the video is spent in Track Mode. The dashboard shows a live circuit map, a list of session lap times, brake and motor temperatures, and pressure and temperature readouts for each tire. A setup page lets the driver pick Auto, Low Drag, High Downforce or Custom aero modes, adjust aero balance and brake balance, and switch stability and traction control off. Along the bottom, a status bar reads “Thruster · 5,500 PSI” next to a “Boost Ready” indicator.

That gauge ties the software to the hardware Tesla showed off near Waco, Texas on October 15. The Thrust and Rocket versions use cold gas thrusters fed by carbon overwrapped pressure vessels, and Tesla lists 0 to 60 mph times of under 0.9 seconds and under 0.59 seconds for them, as Teslarati detailed in its breakdown of the three Roadster configurations. The base Performance car relies on a fan and ground sealing system for grip, and the aero settings on screen match the active wings and suction setup covered in our look at how the Roadster generates downforce.

The Roadster layout is a departure from the rest of Tesla’s lineup. Instead of a map centered screen, the Roadster puts the car itself at the center of the home page, and Tesla’s Roadster page lists two smaller forward displays alongside the main touchscreen. Tesla has not said whether any of the Track Mode telemetry will make its way to the Model 3 Performance or other vehicles.

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The interface could still change before deliveries. Elon Musk said at the event that Roadster production will begin in 2028, and Tesla says the flagship Rocket version is not approved for public road use. Reservations are open with a $50,000 payment, while Thrust is listed as a limited release and Rocket is invite only.

Those who want to see the car in person will get their first chance this weekend. The Roadster goes on display in the lobby of the Petersen Automotive Museum in Los Angeles from October 24 to 27, according to Sawyer Merritt, the first time the public will be able to view it up close.

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Tesla reveals Optimus Academy, where robots teach themselves

Tesla has begun building production quality Optimus robots in Fremont and revealed its training plan.

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Concept rendering of Tesla Optimus in mass production

Tesla has started building Optimus on the high volume line it set up inside its Fremont factory, and the company says the robots coming off it are the first that meet the bar for a real product. “The bots coming off this line are the first production-quality bots that we have manufactured,” Tesla wrote in its third quarter shareholder letter, adding that it has “proven that the current manufacturing process for Optimus is suitable for a commercial product.”

The line sits in space that built the Model S and Model X until this spring. Tesla cleared the old vehicle line in 46 days, as Teslarati reported in July, to make room for robot production sized for one million units a year. On Wednesday’s earnings call, Elon Musk said most of the equipment for that capacity is already in Fremont, with output set to climb toward roughly 20,000 robots a week as the line ramps.

Musk described the ramp as a classic S curve. “The growth of Optimus is an S curve, but the initial curve is a shallow slope,” he said. The team is now refining the robot’s AI, electromechanical design, reliability and service life, and Musk expects that work to be finished by the end of next year, when Tesla plans to start delivering Optimus to outside companies for dangerous, repetitive and around the clock jobs.

The most interesting part of the call was how Tesla plans to teach the robots. Its cars send real driving data back to the AI team from millions of vehicles, but Optimus has no fleet like that yet. “A big difference with Optimus versus the cars is we don’t have this vast fleet of cars from which we can gather training data,” Musk said. Tesla’s answer is an Optimus Academy, where 10,000 to 20,000 robots will practice a wide range of tasks and feed what they learn into the next version of the model. Every unit off the Fremont line becomes a source of that training data.

Smarter hardware is on the way too. Tesla plans to put its AI5 chip into Optimus next year, and Musk said a new Optimus video should arrive within one or two months showing the robot completing tasks driven by AI rather than preprogrammed motions. He took aim at rival humanoid demos that only run scripted routines, saying those would not hold up in the real world.

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The supply chain is lining up behind the program. In September, Tesla certified Tuopu, Joyson and Sanhua as mass production partners for Optimus components. A far larger Optimus factory is also rising at Giga Texas, where drone footage from Joe Tegtmeyer showed the steel frame nearing completion, and Musk has pegged that plant’s long term target at 10 million robots a year.

Tesla executives also said Optimus production costs are trending toward the expected manufacturing cost of Cybercab, a sign the robot is being engineered for volume from the start. The hands remain the toughest piece of the design, a point Musk also made at the X Takeover event earlier this month, as Teslarati covered at the time, and that is where much of the current engineering effort is focused.

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The Starship moon landing number NASA and Elon Musk can’t agree on

Musk disputes NASA estimate of 22 Starship launches for Moon landing, predicting 6 to 8.

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Concept rendering of SpaceX Starship landing on the moon via Grok

Elon Musk is disputing a new NASA safety panel estimate of how many Starship launches it will take to put astronauts on the Moon, saying the real number will be less than half the panel’s figure.

On Thursday, NASA’s Aerospace Safety Advisory Panel held its quarterly public meeting. Panel member Charlie Precourt, a former NASA astronaut, flagged the fueling process for SpaceX’s lunar lander as a major risk for Artemis IV, the mission planned to land a crew on the Moon in 2028. “We need to keep our eyes on numerous required fuelings for the lander,” Precourt said, according to Ars Technica. “I think the last estimate is around 22 flights.”

Ars Technica’s Eric Berger posted the comment on X, and Musk replied. “That’s way too high,” Musk wrote. “Actual number will be more like 6 to 8.”

The disagreement comes down to a basic problem with sending a ship as large as Starship to the Moon. Starship burns nearly all of its propellant just reaching Earth orbit, so it cannot continue on to the Moon without stopping for a refill. SpaceX’s answer is a gas station in space. First, a Starship that works as a storage tank, called a depot, is launched into orbit. Then a series of tanker Starships launch one at a time, dock with the depot and pump their leftover propellant into it. Once the depot is full, the lunar lander version of Starship launches, docks, fills up and heads for the Moon.

Every tanker trip is its own full rocket launch, which is why the count matters. More launches mean more time, more cost and more chances for something to go wrong before astronauts ever leave Earth. Berger estimated that even if SpaceX reaches twice weekly Starship launches by the end of 2027, filling a depot at the panel’s number would still take roughly three months.

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How many tankers are needed depends mostly on how much propellant each one can carry to orbit and how much is lost along the way. Starship’s fuel and oxygen are stored at extremely cold temperatures, and some of it slowly boils off while waiting in orbit. More is lost in each transfer. NASA appears to be working from what Starship can lift today, while Musk’s range assumes a more capable rocket.

Musk has pushed back on higher counts before. In 2021, after a government document suggested 16 launches, he called that “extremely unlikely” and said eight tankers would be the most required.

Much of the answer depends on hardware SpaceX has not finished flying. As Teslarati noted earlier this year, the company plans to carry out the refueling process with its upgraded V3 Starship, and Precourt described Artemis IV as carrying “a large number of firsts.” He also praised NASA Administrator Jared Isaacman’s team for working to clear obstacles for both SpaceX and Blue Origin, whose Blue Moon lander does not rely on orbital refueling for its first mission.

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