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SpaceX to static fire Falcon 9 with a spacecraft on board for the first time in two years

The integrated DM-1 Crew Dragon 'stack' rolled out to Pad 39A for the first time in the first few days of 2019. (SpaceX)

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SpaceX has rolled Falcon 9 and Crew Dragon out to Pad 39A for the second time ever in preparation for a full wet dress rehearsal (WDR) and static fire – no earlier than Jan. 23 – of booster B1051’s nine Merlin 1D engines, preparing for an orbital launch attempt that slipped from NET Feb. 9 to Feb. 16 earlier this week.

While this milestone is important for myriad other reasons, it happens to be exceptionally unique thanks to one particularly surprising feature: Falcon 9 rolled out for its static fire with Crew Dragon (the rocket’s payload) still attached. This will be the first time in more than 28 months – since Amos-6, the last catastrophic Falcon 9 failure – that SpaceX has performed its routine on-pad static fire with a valuable payload attached to the rocket.

On September 1st, 2016, a SpaceX Falcon 9 experienced the rocket family’s second catastrophic failure ever when supercool liquid oxygen froze around a COPV’s carbon fiber wrappings, expanding just enough to breach the ultra-high-pressure vessel. Falcon 9 and its ~$200M Amos-6 satellite payload were completely destroyed, while Launch Complex 40 (LC-40) suffered tens of millions of dollars of damage that would effectively require it to be completely rebuilt over the course of more than a year.

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After Amos-6, SpaceX immediately halted the practice of including customer payloads on Falcon 9 during static fires, used to save 24-48 hours of time between static fire and launch. SpaceX nevertheless retained the option if customers were to explicitly request it, otherwise wisely concluding (likely with more than a little encouragement from insurance companies) that expediting schedules by a few dozen hours was not worth the entirely unnecessary risk to satellite payloads that often cost hundreds of millions of dollars and take years to build.

https://twitter.com/spiel2001/status/1087828282937102338

Given that SpaceX has stuck to that practice for all 38 Falcon 9 launches it has performed between Amos-6 and the present day, it seems all but guaranteed that the first orbit-ready Crew Dragon’s presence on Falcon 9 during its static fire has been done only at the specific request of the launch customer – in this case, NASA. It’s probably not hyperbolic to argue that Demo-1’s (DM-1) Crew Dragon is the most valuable, important, expensive, and irreplaceable spacecraft SpaceX has ever attempted to launch, having likely spent millions of work hours building, changing, refining, and testing it to meet NASA’s exacting and sometimes absurd requirements.

If Falcon 9 B1051 were to fail with Crew Dragon atop it during its Pad 39A static fire, it might be possible for the DM-2’s Crew Dragon to be completed and modified for an uncrewed test flight with just six months of delay, assuming Falcon 9’s mode of failure could be investigated and repaired to NASA’s satisfaction. However, the destruction of the DM-1 capsule and trunk could almost indefinitely delay SpaceX’s first crewed launch, dependent upon an inflight-abort test that is supposed to use the refurbished DM-1 capsule, while the Crew Dragon currently supposed to launch after DM-2 is unlikely to be ready before August or September 2019.

 

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Ultimately, NASA likely requested that Crew Dragon remain atop Falcon 9 for this static fire out of some desire for a full-fidelity test environment and complement of data. There is perhaps a very limited chance that Crew Dragon will be fully fueled with hydrazine (MMH/NTO) and have its launch escape system (LES) active and ready to go in the event of a rocket failure.

Why they deemed the immense potential risk to be worthwhile is far less clear. Whether it is being done out of complacency or a desire for expediency or ultra-realistic test data, the risk is the same. In theory, Falcon 9 has been tested extensively and should operate perfectly, just as expected. So was Amos-6’s Falcon 9.


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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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SpaceX shades airline for seeking contract with Amazon’s Starlink rival

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Credit: Richard Angle

SpaceX employees, including its CEO Elon Musk, shaded American Airlines on social media this past weekend due to the company’s reported talks with Amazon’s Starlink rival, Leo.

Starlink has been adopted by several airlines, including United Airlines, Qatar Airways, Hawaiian Airlines, WestJet, Air France, airBaltic, and others. It has gained notoriety as an extremely solid, dependable, and reliable option for airline travel, as traditional options frequently cause users to lose connection to the internet.

Many airlines have made the switch, while others continue to mull the options available to them. American Airlines is one of them.

A report from Bloomberg indicates the airline is thinking of going with a Starlink rival owned by Amazon, called Leo. It was previously referred to as Project Kuiper.

American CEO Robert Isom said (via Bloomberg):

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“While there’s Starlink, there are other low-Earth-orbit satellite opportunities that we can look at. We’re making sure that American is going to have what our customers need.”

Isom also said American has been in touch with Amazon about installing Leo on its aircraft, but he would not reveal the status of any discussions with the company.

The report caught the attention of Michael Nicolls, the Vice President of Starlink Engineering at SpaceX, who said:

“Only fly on airlines with good connectivity… and only one source of good connectivity at the moment…”

CEO Elon Musk replied to Nicolls by stating that American Airlines risks losing “a lot of customers if their connectivity solution fails.”

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There are over 8,000 Starlink satellites in orbit currently, offering internet coverage in over 150 countries and territories globally. SpaceX expands its array of satellites nearly every week with launches from California and Florida, aiming to offer internet access to everyone across the globe.

SpaceX successfully launches 100th Starlink mission of 2025

Currently, the company is focusing on expanding into new markets, such as Africa and Asia.

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Tesla hints at Starlink integration with recent patent

“By employing polymer blends, some examples enable RF transmission from all the modules to satellites and other communication devices both inside and outside the vehicle.”

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Credit: Grok

Tesla hinted at a potential Starlink internet terminal integration within its vehicles in a recent patent, which describes a vehicle roof assembly with integrated radio frequency (RF) transparency.

The patent, which is Pub. No U.S. 2025/0368267 describes a new vehicle roof that is made of RF-transparent polymer materials, allowing and “facilitating clear communication with external devices and satellites.”

Tesla believes that a new vehicle roof design, comprised of different materials than the standard metallic or glass elements used in cars today, would allow the company to integrate modern vehicular technologies, “particularly those requiring radio frequency transmission and reception.

Instead of glass or metallic materials, Tesla says vehicles may benefit from high-strength polymer blends, such as Polycarbonate, Acrylonitrile Butadiene Styrene, or Acrylonitrile Styrene Acrylate.

These materials still provide ideal strength metrics for crashworthiness, stiffness for noise, vibration, and harshness control, and are compliant with head impact regulations.

They would also enable better performance with modern technologies, like internet terminals, which need an uninterrupted signal to satellites for maximum reception. Tesla writes in the patent:

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“By employing polymer blends, some examples enable RF transmission from all the modules to satellites and other communication devices both inside and outside the vehicle.”

One of the challenges Tesla seems to be aware of with this type of roof design is the fact that it will still have to enable safety and keep that at the forefront of the design. As you can see in the illustration above, Tesla plans to use four layers to increase safety and rigidity, while also combating noise and vibration.

It notes in the patent that disclosed examples still meet the safety requirements outlined in the Federal Motor Vehicle Safety Standards (FMVSS).

Starlink integrated directly into Tesla vehicles would be a considerable advantage for owners. It would come with a handful of distinct advantages.

Initially, the inclusion of Starlink would completely eliminate cellular dead zones, something that is an issue, especially in rural areas. Starlink would provide connectivity in these remote regions and would ensure uninterrupted service during road trips and off-grid adventures.

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It could also be a critical addition for Robotaxi, as it is crucial to have solid and reliable connectivity for remote monitoring and fleet management.

Starlink’s growing constellation, thanks to SpaceX’s routine and frequent launch schedule, will provide secure, stable, and reliable internet connectivity for Tesla vehicles.

SpaceX reaches incredible milestone with Starlink program

Although many owners have already mounted Starlink Mini dishes under their glass roofs for a similar experience, it may be integrated directly into Teslas in the coming years, either as an upgrade or a standard feature.

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Investor's Corner

SpaceX IPO is coming, CEO Elon Musk confirms

However, it appears Musk is ready for SpaceX to go public, as Ars Technica Senior Space Editor Eric Berger wrote an op-ed that indicated he thought SpaceX would go public soon. Musk replied, basically confirming it.

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elon musk side profile
Joel Kowsky, Public domain, via Wikimedia Commons

Elon Musk confirmed through a post on X that a SpaceX initial public offering (IPO) is on the way after hinting at it several times earlier this year.

It also comes one day after Bloomberg reported that SpaceX was aiming for a valuation of $1.5 trillion, adding that it wanted to raise $30 billion.

Musk has been transparent for most of the year that he wanted to try to figure out a way to get Tesla shareholders to invest in SpaceX, giving them access to the stock.

He has also recognized the issues of having a public stock, like litigation exposure, quarterly reporting pressures, and other inconveniences.

However, it appears Musk is ready for SpaceX to go public, as Ars Technica Senior Space Editor Eric Berger wrote an op-ed that indicated he thought SpaceX would go public soon.

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Musk replied, basically confirming it:

Berger believes the IPO would help support the need for $30 billion or more in capital needed to fund AI integration projects, such as space-based data centers and lunar satellite factories. Musk confirmed recently that SpaceX “will be doing” data centers in orbit.

AI appears to be a “key part” of SpaceX getting to Musk, Berger also wrote. When writing about whether or not Optimus is a viable project and product for the company, he says that none of that matters. Musk thinks it is, and that’s all that matters.

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It seems like Musk has certainly mulled something this big for a very long time, and the idea of taking SpaceX public is not just likely; it is necessary for the company to get to Mars.

The details of when SpaceX will finally hit that public status are not known. Many of the reports that came out over the past few days indicate it would happen in 2026, so sooner rather than later.

But there are a lot of things on Musk’s plate early next year, especially with Cybercab production, the potential launch of Unsupervised Full Self-Driving, and the Roadster unveiling, all planned for Q1.

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