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SpaceX’s Falcon Heavy shown launching NASA Orion spacecraft in fan render

NASA's Orion spacecraft (left) and SpaceX's Falcon Heavy rocket (right). (NASA/SpaceX)

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8 years ago

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A spaceflight fan’s unofficial render has offered the best look yet at what SpaceX’s Falcon Heavy could look like in the unlikely but not impossible event that NASA decides to launch its uncrewed Orion demonstration mission on commercial rockets.

Oddly enough, the thing that most stands out from artist brickmack’s interpretation of Orion and Falcon Heavy is just how relatively normal the large NASA spacecraft looks atop a SpaceX rocket. The render also serves as a visual reminder of just how little SpaceX would necessarily need to change or re-certify before Falcon Heavy would be able to launch Orion. Aside from the fact that NASA’s Launch Services Program (LSP) is not quite ready to certify the full launch vehicle for NASA missions, very few hurdles appear to stand in the way of Orion launching on a commercial rocket – be it on Falcon Heavy or ULA’s Delta IV Heavy.

In a wholly unexpected announcement made by NASA administrator Jim Bridenstine during a March 13th Congressional hearing, the agency leader revealed that NASA was seriously analyzing the possibility of launching Orion’s uncrewed lunar demonstration mission – known as Exploration Mission 1 (EM-1) – on commercial launch vehicles instead of the agency’s own Space Launch System (SLS) rocket.

The purpose: maintain the missions launch schedule – 2020 – in the face of a relentless barrage of delays facing the SLS rocket, the launch debut of which has effectively been slipped almost three years in the last 18 or so months, with the latest launch date now featuring a median target of November 2021. Some subset of NASA leaders, Congressional supporters, and White House officials have clearly begun to accept that SLS/Orion’s major continued delays are simply unacceptable to both the taxpayer and maintaining appearances, despite the fact that those delays continue to make SLS/Orion an extremely successful example of both corporate welfare and a jobs program.

As it currently stands, a median target of November 2021 for the SLS launch debut guarantees that there is almost certainly no chance of the rocket launching at any point in 2020, even if NASA took the extraordinary step of completely cutting a full-length static fire of the entirely unproven rocket prior to its debut. Known as the “Green Run”, the ~8-minute long static fire test is planned to occur at NASA’s Stennis Space Center on the B2 test stand, which NASA – despite continuous criticism from OIG before and after the decision – has spent more than $350M to refurbish. Stennis B2’s refurbishment was effectively completed just two months ago after the better part of seven years of work.

Put simply, even heroics verging on insanity would be unlikely to get SLS prime contractor Boeing to cut ~12 months off of the rocket’s schedule prevent additional unplanned delays in the 18 or so months between now and an even minutely plausible launch debut target. Admittedly, NASA’s proposed commercial alternative for Orion’s lunar launch debut also offers a range of different but equally concerning risks for the program and mission assurance.

Falcon Heavy in its currently-unflown Block 5 configuration. (SpaceX)
NASA’s SLS rocket seen in its Block 1 configuration with on Orion capsule on top. (NASA)

Major challenges remain

On one hand, the task of successfully launching NASA’s Orion spacecraft around the Moon with Delta IV Heavy and Falcon Heavy rockets has a lot going for it, regardless of which rockets launch Orion to LEO or launch the fueled upper stage to boost it around the Moon. In 2014, NASA and ULA successfully launched a partial-fidelity Orion spacecraft to an altitude of 3700 miles (~6000 km), testing some of Orion’s avionics, general spacefaring capabilities, and the craft’s heat shield, although Lockheed Martin has since significantly changed the shield’s design and method of production/installation. Regardless, the EFT-1 test flight means that a solution already more or less exists to mate Orion and its service module (ESM) to a commercial rocket and launch the duo into orbit.

If ULA is unable to essentially produce a Delta IV Heavy from scratch in less than 12-18 months, Falcon Heavy would be next in line to launch Orion/ESM, a use-case that might actually be less absurd than it seems. Thanks to the fact that SpaceX’s payload fairing is actually wider than the large Orion spacecraft (5.2 m (17 ft) vs. 5 m (16.5 ft) in diameter), any major risks of radical aerodynamic problems can be largely retired, although that would still need to be verified with models and/or wind-tunnel testing. The only major change that would need to be certified is ensuring that the Falcon second stage is capable of supporting the Orion/ESM payload, weighing at least ~26 metric tons (~57,000 lb) at launch. The heaviest payloads SpaceX has launched thus far were likely its Iridium NEXT missions, weighing around 9600 kg (21,100 lb).

  • A partial fidelity Orion prototype is pictured here atop ULA's Delta IV Heavy rocket prior to a 2014 test launch. (NASA)
  • The Orion spacecraft and service module. (NASA)

However, the most difficult aspects of Bridenstine’s proposed alternative are centered around the need for the EM-1 Orion spacecraft to somehow dock with a fueled upper stage meant to be launched separately. Orion in its current EM-1 configuration does not currently have the ability to dock with anything on orbit, a challenge that would require Lockheed Martin and subcontractors to find a way to install the proper hardware and computers and develop software that was – prior to this surprise announcement – only planned to fly on EM-3 (NET 2024). As such, Lockheed Martin – notorious for slow progress, cost overruns, and delays throughout the Orion program – would effectively become the critical path in finishing and installing on-orbit docking capabilities on Orion in less than 12-18 months.

The only alternative would be to have either SpaceX or ULA retrofit some sort of docking mechanism onto one of their upper stages, perhaps less difficult than getting Lockheed Martin to work expediently but still a major challenge for such a short developmental timeframe. Put simply, completing the tasks at hand in the time allotted could easily be beyond the capabilities of old-guard NASA contractors like LockMart and Boeing. Ironically, the upper stage that was designed for EM-1 and is already more or less complete – known as the interim cryogenic propulsion stage (ICPS) – is built by Boeing, the same company that has the most to lose if NASA chooses to make the SLS rocket – which Boeing also builds – functionally redundant with a commercial dual-launch alternative.

Boeing (as part of ULA) effectively completed the first ICPS upper stage for SLS near the end of 2016. It has remained in storage for about two years. (NASA/ULA)

With information currently available, it’s thus reasonable to argue that both launching SLS/Orion in 2020 and launching Orion on Falcon Heavy and/or Delta IV Heavy in 2020 are roughly equal in the level of ambition (insanity?) and increased risk required to attempt either. The question, then, is which risky and extremely difficult challenge – versus doing nothing – is most likely to be in NASA’s best interests?

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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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Elon Musk

Elon Musk shuts down talk of TSMC taking over Terafab

Musk says Tesla and SpaceX will build and run Terafab, with TSMC limited to renting.

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5 hours ago

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October 7, 2026

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SpaceX Terafab rendering

Elon Musk has drawn a firm line around who will be in charge of Terafab, the giant chip factory Tesla and SpaceX are planning in Texas.

Musk replied to a post on X arguing that Taiwan Semiconductor Manufacturing Company (TSMC) would most likely end up owning and operating the plant. “No, we will build and run the fab. Let there be ZERO doubt about that,” Musk wrote. “Maybe TSMC subleases part of the Terafab if they want, but nothing more than that.”

In plain terms, a sublease means TSMC could rent a section of the complex to make chips, similar to a tenant renting one floor of an office tower. The building, the equipment decisions and the daily operation would stay with Tesla and SpaceX.

The comment shuts down speculation that started last week. On October 2, tech journalist Tim Culpan reported that TSMC was exploring ways to help run Terafab’s factories. Musk responded the next day that it was “just discussions, but something may come of it,” as Teslarati reported at the time. That left room for a scenario where the world’s largest contract chipmaker took the wheel. Musk’s latest post closes that door.

Elon Musk teases TSMC as potential Terafab partner

Some background helps explain why this matters. Tesla designs its own AI chips today but pays outside companies like TSMC and Samsung to manufacture them. Musk unveiled Terafab in March as a joint project between Tesla, SpaceX and xAI, arguing that existing suppliers cannot expand fast enough to meet his companies’ future demand. The goal is to produce enough chips each year to supply one terawatt of computing power, roughly 50 times what the entire global AI chip industry produces now.

Those chips are meant for Tesla’s Optimus humanoid robots, the Cybercab and Full Self-Driving computers, along with chips for SpaceX’s planned data centers in orbit. Owning the factory means Musk’s companies would not have to compete with every other chip customer for time on someone else’s production lines.

Intel is still part of the picture. The company signed on in April to help design, build and package chips for the project, and CEO Lip-Bu Tan told Bloomberg this week that Intel will keep working on Terafab despite the TSMC chatter.

The project moved from concept to construction planning over the summer. In August, SpaceX confirmed the Grimes County site about an hour from Houston, sent the county a $10 million payment under its tax abatement deal and said civil work would begin shortly. The first phase carries a $16.8 billion price tag, and total spending across all phases could reach as much as $119 billion.

TSMC chairman C.C. Wei has said a new fab typically takes two to three years to build and another one to two years to reach full output. Tesla and SpaceX have never run one, which is why TSMC’s expertise drew so much attention. Musk’s answer suggests he would rather learn that process in house than hand control of a project this central to Tesla’s robotics and autonomy plans to an outside company.

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Elon Musk

Trump to hand Elon Musk a top honor that traces back to JFK

Trump will award Elon Musk the National Medal of Science at Thursday’s White House summit.

Published

12 hours ago

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October 7, 2026

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elon musk and donald trump in front of a tesla cybertruck at the white house

Elon Musk is set to receive the highest honor the U.S. government gives to scientists and engineers.

President Donald Trump will present Musk with the National Medal of Science on Thursday at the White House’s Science: A New Golden Age Summit, Fox News Digital first reported on Wednesday. Google cofounder Sergey Brin, Nvidia CEO Jensen Huang and AMD CEO Lisa Su will receive the same medal, while Dell Technologies CEO Michael Dell and Microsoft CEO Satya Nadella will receive the National Medal of Technology and Innovation. A White House official later confirmed the list to Reuters.

“The Trump administration is grateful for the contributions of these incredible leaders in science and technology. These recipients are helping ensure America keeps leading the world in innovation,” White House spokesperson Liz Huston told Fox News.

It will be the first time Trump has presented either medal in his two terms. Congress created the National Medal of Science in 1959, and the National Science Foundation, which administers it, says 529 scientists and engineers have received it since. A presidential committee reviews nominees, but the president makes the final call.

Thursday’s group of medalists run or founded companies, and three of them sit at the center of the Super Intelligence hardware race that Musk competes in. Huang’s Nvidia supplies the GB300 chips filling SpaceX’s Colossus 2 cluster, while Su’s AMD is Nvidia’s biggest rival in data center GPUs.

Worth noting that Trump’s uncle, MIT physicist John G. Trump, received the National Medal of Science from President Ronald Reagan for his work on ionizing radiation and its uses in medicine and industry.

The Pentagon taps Elon Musk to design the battlefield of the future

For Musk, the medal is the latest sign of how far his relationship with Trump has come since their 2025 split over the “Big Beautiful Bill” and his exit from DOGE. Last week, he sat at Trump’s left during a White House lunch where AI executives signed a voluntary safety accord, and Defense Secretary Pete Hegseth named him to help lead the Pentagon’s Project Meridian study on the future of warfare. Musk has also adopted the administration’s new vocabulary, saying on Sunday that SpaceXAI will be renamed SpaceXSI after Trump ordered federal agencies to replace “artificial intelligence” with “super intelligence.”

Musk has collected science honors before, including the Stephen Hawking Medal for Science Communication in 2019.

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Investor's Corner

SpaceX reveals how its 1 Million AI satellite network will work and prevent space collisions

SpaceX reveals plans for one million Starmind AI satellites and calls out operators hiding maneuvers.

Published

2 days ago

on

October 6, 2026

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Concept rendering of SpaceX Starmind constellation via Grok
Concept rendering of SpaceX Starmind constellation via Grok

SpaceX has put the largest satellite count it has ever published into writing, and it says that plan only works if every other operator in orbit starts sharing what it knows.

In a new Space Safety page highlighted Tuesday morning by Sawyer Merritt on X, SpaceX said it “plans to operate up to 100,000 Starlink satellites and up to 1 million Starmind AI satellites to meet the growing demand for broadband and supercompute.” Starlink has a little over 11,000 satellites in orbit today, so the target alone implies roughly a ninefold expansion of the broadband network.

Starmind is SpaceX’s orbital AI compute constellation. Elon Musk confirmed the Starmind name in June after an xAI trademark filing surfaced, and in August SpaceX said it was working with Nvidia on the compute payload. The FCC accepted the filing for up to one million satellites back in February.

FCC accepts SpaceX filing for 1 million orbital data center plan

SpaceX also released a new render of what a full Starmind constellation could look like. Alongside it, SpaceX VP Michael Nicolls explained why the satellites will not operate on their own. “We need to operate clusters of satellites in tight formation to get enough coherent compute to run AI models efficiently,” Nicolls said. “A cluster will be 10-ish satellites connected with 10 terabits or so of bandwidth between them, and interconnected to the broader constellation.”

That is the most specific detail SpaceX has given on how Starmind will be built. Instead of a million independent servers, the network would work as tightly packed groups of about 10 satellites acting as one compute unit, with Starlink’s laser links carrying results back to Earth.


Packing satellites that close together, at that scale, makes collision avoidance the central problem, and most of the Space Safety page is aimed at other operators. SpaceX said Starlink encountered collision risks with about 650 unique maneuvering third party satellites in 2026, and only about half of them shared data. Over six months, Starlink recorded roughly 164,000 more collision risks where the closest approach came within four hours of an unannounced maneuver.

Some operators keep maneuver plans private over proprietary concerns, while others cannot get government permission to share them. SpaceX called those policies “counterproductive,” saying they “largely only serve to create preventable collision risk between satellites.” Starlink is also offering a free ephemeris sharing and screening platform that returns risk results within a minute, backed by its Stargaze network of 30,000 optical sensors.

The push comes as the Starmind application draws opposition from astronomers and environmental groups. In a September filing with the FCC, SpaceX said each Starmind satellite could weigh up to 4,000 kg, nearly seven times the mass of a Starlink V2 Mini. Musk has brushed off crowding concerns before, telling viewers in June that “space is enormous” and that SpaceX already knows how to run very large constellations safely.

SpaceX’s Starmind page says its Gigasat factory in Bastrop, Texas, is designed to produce AI satellites at scale, with deployment of thousands of units starting as soon as late 2027.

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