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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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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).

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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Starship Flight 10 rescheduled as SpaceX targets Monday launch

SpaceX said it is now targeting Monday evening for Starship’s 10th flight test.

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Credit: SpaceX/X

SpaceX stood down from its planned Starship Flight 10 on Sunday evening, citing an issue with ground systems. 

The launch attempt was scheduled during a one-hour window that opened at 7:30 p.m. ET, but it was called off just 17 minutes before the window opened. SpaceX said it is now targeting Monday evening for Starship’s 10th flight test.

Flight 10 rescheduled

A lot of excitement was palpable during the lead up to Starship Flight 10’s first launch window. After the failures of Starship Flight 9, many were interested to see if SpaceX would be able to nail its mission objectives this time around. Starship itself seemed ready to fly, with the upper stage being loaded with propellant as scheduled. Later on, SpaceX also noted that Starship’s Super Heavy booster was also being loaded with propellant.

However, 17 before the launch window opened, SpaceX noted that it was “standing down from today’s tenth flight of Starship to allow time to troubleshoot an issue with ground systems.” Elon Musk, in a post on X, further clarified that a “ground side liquid oxygen leak needs to be fixed.” Musk did state that SpaceX will attempt Flight 10 again on Monday, August 25, 2025.

Starship and SpaceX’s development goals

The fully integrated Starship system is the tallest and most powerful rocket ever built, standing over 400 feet when stacked. Composed of the reusable Super Heavy booster and the Starship upper stage, the vehicle is central to SpaceX’s long-term ambitions of lunar and Martian missions. NASA has already selected Starship as the crewed lunar lander for Artemis, with its first astronaut landing mission tentatively set for 2027, as noted in a Space.com report.

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So far, Starship has flown nine times from Starbase in Texas, with three launches this year alone. Each flight has offered critical data, though all three 2025 missions encountered notable failures. Flight 7 and Flight 8 ended in explosions less than 10 minutes after launch, while Flight 9 broke apart during reentry. Despite setbacks, SpaceX has continued refining Starship’s hardware and operations with each attempt. Needless to say, a successful Flight 10 would be a significant win for the Starship program.

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SpaceX Starship Flight 10: What to expect

SpaceX implemented hardware and operational changes aimed at improving Starship’s reliability.

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Credit: SpaceX

SpaceX is preparing to launch the tenth test flight of its Starship vehicle as early as Sunday, August 24, with the launch window opening at 6:30 p.m. CT. 

The mission follows investigations into anomalies from earlier flights, including the loss of Starship on its ninth test and a Ship 36 static fire issue. SpaceX has since implemented hardware and operational changes aimed at improving Starship’s reliability.

Booster landing burns and flight experiments

The upcoming Starship Flight 10 will expand Super Heavy’s flight envelope with multiple landing burn trials. Following stage separation, the booster will attempt a controlled flip and boostback burn before heading to an offshore splashdown in the Gulf of America. One of the three center engines typically used for landing will be intentionally disabled, allowing engineers to evaluate whether a backup engine can complete the maneuver, according to a post from SpaceX.

The booster will also transition to a two-engine configuration for the final phase, hovering briefly above the water before shutdown and drop. These experiments are designed to simulate off-nominal scenarios and generate real-world data on performance under varying conditions, while maximizing propellant use during ascent to enable heavier payloads.

Starship upper stage reentry tests

The Starship upper stage will attempt multiple in-space objectives, including deployment of eight Starlink simulators and a planned Raptor engine relight. SpaceX will also continue testing reentry systems with several modifications. A section of thermal protection tiles has been removed to expose vulnerable areas, while new metallic tile designs, including one with active cooling, will be trialed.

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Catch fittings have been installed to evaluate their thermal and structural performance, and adjustments to the tile line will address hot spots observed on Flight 6. The reentry profile is expected to push the structural limits of Starship’s rear flaps at maximum entry pressure.

SpaceX says lessons from these tests are critical to refining the next-generation Starship and Super Heavy vehicles. With Starfactory production ramping in Texas and new launch infrastructure under development in Florida, the company is pushing to hit its goal of achieving a fully reusable orbital launch system.

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FAA clears SpaceX for Starship Flight 10 after probe into Flight 9 mishap

SpaceX will attempt a Gulf splashdown for Flight 10 once more instead of a tower capture.

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Credit: SpaceX

The Federal Aviation Administration has closed its review of SpaceX’s Starship Flight 9 mishap, clearing the way for the next launch attempt as soon as August 24. 

Flight 9 ended with the loss of both the Super Heavy booster and the upper stage, but regulators accepted SpaceX’s findings that a fuel component failure was the root cause. No public safety concerns were reported from the incident.

Starship recovery lessons

SpaceX noted that Flight 9 marked the first reuse of a Super Heavy booster. Unlike prior attempts, the company did not try a tower “chopsticks” recovery, opting instead for an offshore return that ended in a destructive breakup. The upper stage was also lost over the Indian Ocean. 

As per the FAA in its statement, “There are no reports of public injury or damage to public property. The FAA oversaw and accepted the findings of the SpaceX-led investigation. The final mishap report cites the probable root cause for the loss of the Starship vehicle as a failure of a fuel component. SpaceX identified corrective actions to prevent a reoccurrence of the event.”

SpaceX also highlighted that Flight 9’s debris did not harm any wildlife. “SpaceX works with an experienced global response provider to retrieve any debris that may wash up in South Texas and/or Mexico as a result of Starship flight test operations. During the survey of the expected debris field from the booster, there was no evidence of any floating or deceased marine life that would signal booster debris impact harmed animals in the vicinity,” the private space company noted.

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Expanding test objectives

To mitigate risks, SpaceX plans to adjust return angles for future flights and conduct additional landing burn tests on Flight 10. SpaceX will attempt a Gulf splashdown for Flight 10 once more, instead of a tower capture, according to a report from the Boston Herald.

The upcoming Starship Flight 10, which will be launching from Starbase in Texas, will also mark SpaceX’s attempt to perform its first payload deployment and an in-space Raptor relight. Despite recent setbacks, which include the last three flights ending with the upper stage experiencing a rapid unscheduled disassembly (RUD), Starship remains central to NASA’s Artemis program, with a variant tapped as the human landing system for Artemis III, the first since the Apollo program. 

Standing more than 400 feet tall and generating 16 million pounds of thrust, Starship remains the most powerful rocket flown, though it has yet to complete an orbital mission. The FAA has expanded SpaceX’s license to allow up to 25 Starship flights annually from Texas.

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