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SpaceX’s attempts to buy bigger Falcon fairings complicated by contractor’s ULA relationship

RUAG (right) builds similar payload fairings for Ariane 5/6, Atlas V, and (soon) Vulcan. SpaceX (left) builds its own Falcon fairings in-house. (SpaceX/RUAG)

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According to a report from SpaceNews, SpaceX recently approached global aerospace supplier RUAG with the intention of procuring a new, larger payload fairing for its Falcon 9 and Heavy rockets.

RUAG is a prolific supplier of rocket fairings, spacecraft deployment mechanisms, and other miscellaneous subassemblies and components, and US company United Launch Alliance (ULA) has relied on RUAG for fairings and various other composites work for its Atlas V, Delta IV, and (soon) Vulcan launch vehicles. According to SpaceNews, that close relationship with ULA forced RUAG to turn SpaceX away, owing to ULA’s argument that the specific fairing technology SpaceX was pursuing is ULA’s intellectual property. The ramifications of this development are not earthshaking but they’re still worth exploring.

Update: A more recent report by SpaceNews seemingly revealed that RUAG has no such exclusivity or IP agreement with ULA. Nevertheless, it’s worth noting that the reality is probably somewhere in between RUAG’s official statement and the more incendiary information that preceded it. As a commercial entity, RUAG is in no way obligated to supply hardware or services to any prospective buyer, and the political and economic ties between ULA and RUAG are likely more influential than public statements will ever acknowledge.

“In a June 12 letter to Smith, the company’s CEO Peter Guggenbach makes the case that legislation forcing access to suppliers is unnecessary in this case because RUAG does not have an exclusive arrangement with ULA and is willing to work with SpaceX or any other launch providers.

“For this competition, we are in the process of submitting or have submitted proposals to multiple prime contractors regarding launch vehicle fairings. In those agreements, we share technical data to support a prime contractor’s bid while protecting our intellectual property.”

RUAG vice president Karl Jensen told SpaceNews the company has a “significant partnership” with ULA but is looking to work with others too. “We have an offer to SpaceX,” he said. “We don’t know if they’ll accept it.”

SpaceNews, 06/13/2019

Additionally, it’s likely that SpaceX is interested in procuring a few RUAG fairings not for the 5.4m diameter – the actual usable diameter is almost the same as Falcon 9’s own fairing – but for the added height, up to ~16.5m compared to F9’s ~11m.

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New fairing needed

According to rules behind the latest phase of the US Air Force military launch competition (LSA Phase 2), competitors – likely to include ULA (Vulcan), Blue Origin (New Glenn), Northrop Grumman (Omega), and SpaceX (Falcon 9/Heavy) – will have to offer a larger, 5.4-meter (17 ft) diameter payload fairing to compete for any of the several dozen launch contracts up for grabs.

SpaceX has worked with RUAG several times in the past due to the company’s involvement in numerous satellite dispensers.

SpaceX’s Falcon 9 and Heavy rockets were designed with a 5.2m-diameter fairing that flew on the very first Falcon 9 launch and continues to be SpaceX’s only fairing today, albeit with several major modifications and upgrades since its 2010 debut. Blue Origin plans to jump straight into 7m-diameter fairing development for its large New Glenn launch vehicle, expected to launch for the first time no earlier than (NET) 2021.

Procured from RUAG, ULA has several fairing options, including its largest, a 5.4m-diameter fairing that flies on Atlas V 500-series vehicles and also flies on Arianespace’s Ariane 5. Northrop Grumman’s (formerly Orbital ATK’s) Omega will feature a 5.25m-diameter fairing if the rocket makes it to flight hardware production.

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The USAF awarded major vehicle development funding to ULA, Orbital ATK (now NGIS), and Blue Origin. SpaceX was snubbed but is still eligible to compete for Phase 2 launch contracts. (Teslarati – ULA/NGIS/Blue Origin/SpaceX)

Although most of the two-dozen or so satellites to be launched as part of LSA Phase 2 are likely small enough to fit Falcon’s 5.2m fairing and Omega’s 5.25m fairing, SpaceX (and Northrop Grumman) would presumably miss out on opportunities to launch those larger (and likely higher-profile) satellites, effectively handing the contracts to Blue Origin or ULA. SpaceX is thus faced with a conundrum that has three possible solutions.

  1. Build a brand new fairing with a significantly larger diameter (5.4m+) and be forced to buy tens of millions of dollars of custom tooling and new manufacturing space for a handful of rare launches with a rocket family meant to be made redundant by Starship/Super Heavy.
  2. Buy a handful of 5.4m-diameter fairings from RUAG, the only practical commercial source on Earth.
  3. Forgo the ability to compete for the few launches that require a larger fairing.

With #2 reportedly removed by ULA’s interference for dubious reasons, the the remaining options are unsavory at best. It’s possible that SpaceX will willingly design, build and certify an entirely new Falcon fairing for US military launches, but the expense of that process – likely $50M-$100M or more – means that it would probably be contingent upon SpaceX receiving the $500M it has recently begun lobbying for.

SpaceX builds all large Falcon 9 and Heavy composite structures in house, including landing legs, interstages, and payload fairings. (SpaceX, 2016)
A Falcon 9 fairing – with the Es-hail 2 communications satellite sealed inside – is transported inside Pad 39A’s hangar to be attached to Falcon 9. (Instagram)

For reference, all three of the launch providers SpaceX is competing against – ULA, NGIS, and Blue Origin – were respectively awarded ~$970M, ~$790M, and $500M by the US Air Force to complete the development of their respective launch vehicles. SpaceX can technically compete in the ~30 launch contract competition to follow, but the company wouldn’t receive a penny of development funding to meet the same requirements its competitors are being paid hundreds of millions of dollars for. In lieu of this undeniable imbalance, SpaceX – via Congressman Adam Smith – secured language in the FY2020 National Defense Authorization Act that would provide the company $500M (equivalent to Blue Origin’s award) if they win one of Phase 2’s two block-buy contracts.

Despite the fact that the USAF has plans to spend more than $2B assisting the development of three new rockets, LSA Phase 2 procurement has been inexplicably structured in such a way that only two companies/rockets can win, with one receiving 60% of contracts and the other receiving 40%. In other words, with that baffling award structure and under the assumption that SpaceX wins one of the slots, two of the three rockets the USAF is throwing money at will either die on the drawing board (Omega) or have a significantly lower chance of achieving military launch certification (New Glenn).

Ultimately, it’s clear that building an entirely new fairing would be valuable for SpaceX, even if it might be extremely expensive and of dubious strategic merit alongside the simultaneously development of Starship/Super Heavy, a vehicle that will feature a reusable 9m-diameter payload bay. Whether or not SpaceX bites that particular bullet, the LSA Phase 2 competition remains as baffling and fascinating as ever.

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 UK sales see 14% year-over-year rebound in June: SMMT data

The SMMT stated that Tesla sales grew 14% year-over-year to 7,719 units in June 2025.

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Credit: Tesla

Tesla’s sales in the United Kingdom rose in June, climbing 14% year-over-year to 7,719 units, as per data from the Society of Motor Manufacturers and Traders (SMMT). The spike in the company’s sales coincided with the first deliveries of the updated Model Y last month.

Model Y deliveries support Tesla’s UK recovery

Tesla’s June performance marked one of its strongest months in the UK so far this year, with new Model Y deliveries contributing significantly to the company’s momentum. 

While the SMMT listed Tesla with 7,719 deliveries in June, independent data from New AutoMotive suggested that the electric vehicle maker registered 7,891 units during the month instead. However, year-to-date figures for Tesla remain 2% down compared to 2024, as per a report from Reuters.

While Tesla made a strong showing in June, rivals are also growing. Chinese automaker BYD saw UK sales rise nearly fourfold to 2,498 units, while Ford posted the highest EV growth among major automakers, with a more than fourfold increase in the first half of 2025.

Overall, the UK’s battery electric vehicle (BEV) demand surged 39% to to 47,354 units last month, helping push total new car sales in the UK to 191,316 units, up 6.7% from the same period in 2024.

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EV adoption accelerates, but concerns linger

June marked the best month for UK car sales since 2019, though the SMMT cautioned that growth in the electric vehicle sector remains heavily dependent on discounting and support programs. Still, one in four new vehicle buyers in June chose a battery electric vehicle.

SMMT Chief Executive Mike Hawes noted that despite strong BEV demand, sales levels are still below regulatory targets. “Further growth in sales, and the sector will rely on increased and improved charging facilities to boost mainstream electric vehicle adoption,” Hawes stated.

Also taking effect this week was a new US-UK trade deal, which lowers tariffs on UK car exports to the United States from 27.5% to 10%. The agreement could benefit UK-based EV producers aiming to expand across the country.

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Tesla Model 3 ranks as the safest new car in Europe for 2025, per Euro NCAP tests

Despite being on the market longer than many of its rivals, the Tesla Model 3 continues to set the bar for vehicle safety.

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Credit: Tesla Asia/X

The Tesla Model 3 has been named the safest new car on sale in 2025, according to the latest results from the Euro NCAP. Among 20 newly tested vehicles, the Model 3 emerged at the top of the list, scoring an impressive 359 out of 400 possible points across all major safety categories.

Tesla Model 3’s safety systems

Despite being on the market longer than many of its rivals, the Tesla Model 3 continues to set the bar for vehicle safety. Under Euro NCAP’s stricter 2025 testing protocols, the electric sedan earned 90% for adult occupant protection, 93% for child occupant protection, 89% for pedestrian protection, and 87% for its Safety Assist systems.

The updated Model 3 received particular praise for its advanced driver assistance features, including Tesla’s autonomous emergency braking (AEB) system, which performed well across various test scenarios. Its Intelligent Speed Assistance and child presence detection system were cited as noteworthy features as well, as per a WhatCar report.

Other notable safety features include the Model 3’s pedestrian-friendly pop-up hood and robust crash protection for both front and side collisions. Euro NCAP also highlighted the Model 3’s ability to detect vulnerable road users during complex maneuvers, such as turning across oncoming traffic.

Euro NCAP’s Autopilot caution

While the Model 3’s safety scores were impressive across the board, Euro NCAP did raise concerns about driver expectations of Tesla’s Autopilot system. The organization warned that some owners may overestimate the system’s capabilities, potentially leading to misuse or inattention behind the wheel. Even so, the Model 3 remained the highest-scoring vehicle tested under Euro NCAP’s updated criteria this year.

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The Euro NCAP’s concerns are also quite interesting because Tesla’s Full Self-Driving (FSD) Supervised, which is arguably the company’s most robust safety suite, is not allowed for public rollout in Europe yet. FSD Supervised would allow the Model 3 to navigate inner city streets with only minimal human supervision.

Other top scorers included the Volkswagen ID.7, Polestar 3, and Geely EX5, but none matched the Model 3’s total score or consistency across categories. A total of 14 out of 20 newly tested cars earned five stars, while several models, including the Kia EV3, MG ZS, and Renault 5, fell short of the top rating.

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Why Tesla’s Q3 could be one of its biggest quarters in history

Tesla could stand to benefit from the removal of the $7,500 EV tax credit at the end of Q3.

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(Credit: Tesla)

Tesla has gotten off to a slow start in 2025, as the first half of the year has not been one to remember from a delivery perspective.

However, Q3 could end up being one of the best the company has had in history, with the United States potentially being a major contributor to what might reverse a slow start to the year.

Earlier today, the United States’ House of Representatives officially passed President Trump’s “Big Beautiful Bill,” after it made its way through the Senate earlier this week. The bill will head to President Trump, as he looks to sign it before his July 4 deadline.

The Bill will effectively bring closure to the $7,500 EV tax credit, which will end on September 30, 2025. This means, over the next three months in the United States, those who are looking to buy an EV will have their last chance to take advantage of the credit. EVs will then be, for most people, $7,500 more expensive, in essence.

The tax credit is available to any single filer who makes under $150,000 per year, $225,000 a year to a head of household, and $300,000 to couples filing jointly.

Ending the tax credit was expected with the Trump administration, as his policies have leaned significantly toward reliance on fossil fuels, ending what he calls an “EV mandate.” He has used this phrase several times in disagreements with Tesla CEO Elon Musk.

Nevertheless, those who have been on the fence about buying a Tesla, or any EV, for that matter, will have some decisions to make in the next three months. While all companies will stand to benefit from this time crunch, Tesla could be the true winner because of its sheer volume.

If things are done correctly, meaning if Tesla can also offer incentives like 0% APR, special pricing on leasing or financing, or other advantages (like free Red, White, and Blue for a short period of time in celebration of Independence Day), it could see some real volume in sales this quarter.

Tesla is just a shade under 721,000 deliveries for the year, so it’s on pace for roughly 1.4 million for 2025. This would be a decrease from the 1.8 million cars it delivered in each of the last two years. Traditionally, the second half of the year has produced Tesla’s strongest quarters. Its top three quarters in terms of deliveries are Q4 2024 with 495,570 vehicles, Q4 2023 with 484,507 vehicles, and Q3 2024 with 462,890 vehicles.

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