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SpaceX’s Falcon Heavy rocket could launch a NASA space station to the Moon

SpaceX's Falcon Heavy rocket could potentially launch a new NASA space station all the way to the Moon. (SpaceX)

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According to NASA, a SpaceX Falcon Heavy rocket (or another commercial heavy-lift launch vehicle) could potentially launch the bulk of a new Moon-orbiting space station in a single go, saving money and reducing risk.

Known as the Gateway, NASA is working to build a tiny space station in an exotic and odd orbit around the Moon. Lacking any clear and pressing purpose, NASA and the Gateway’s proponents have argued that it could serve as a testbed for interplanetary missions, allowing the space agency to figure out how to keep astronauts alive and healthy in deep space. Later, it was proposed as a sort of unwieldy orbital tug and home base for crewed Moon landers, although the Gateway appears to have recently been removed from any plans for mid-2020s Moon landings.

Most likely, the station is being built in order to give NASA’s wildly over-budget, behind-schedule Orion spacecraft and SLS rocket some kind of destination worthy of their gobsmacking $2-3 billion launch cost and $35-40 billion development cost. Regardless, a space station orbiting the Moon – while lacking a clear and present scientific or exploratory reason for its existence – is undeniably cool and exciting and will indeed need to be launched into cislunar space. Previously planned to launch as separate modules that would then rendezvous and dock in at the Moon, NASA has recently decided to switch gears.

According to NASA, the near-term arrival of launch vehicles with extra-large commercial fairings has motivated a change in its space station launch strategy. (SpaceX)

As of May 2020, NASA has awarded three critical hardware contracts for Gateway. In 2019, the space agency awarded contracts to Maxar and Northrop Grumman to build the Power and Propulsion Element (PPE) and Habitation and Logistics Outpost (HALO), respectively. As the name suggests, the PPE will feature an exceptionally large ~50 kW solar array and the most powerful electric thrusters ever flown in space, thus supplying Gateway with electricity and propulsion. HALO is a miniscule habitat module also responsible for life support and providing all other basic necessities for astronauts to live in space, all of which will leave a tiny amount of actual habitable volume for those astronauts to live in.

Most recently, NASA also awarded SpaceX a contract to develop a new Dragon XL spacecraft that will launch on Falcon Heavy and autonomously resupply the lunar space station at least twice, should Gateway actually make it to launch.

NASA has selected SpaceX to deliver cargo to its upcoming Lunar Gateway. Credit: SpaceX
The Maxar PPE (far left) and (two) Northrop Grumman HALO modules are pictured here, as well as an Orion spacecraft (far right). (Northrop Grumman)

The notional plan is to eventually expand the habitable volume of the station from living in a large SUV to something more like a small studio apartment, a bit less than a third as large as the International Space Station (ISS) in a best-case scenario. The ISS is designed to support at least six astronauts simultaneously and has done so for almost two decades, albeit only with the help of resupply missions launched from Earth every 2-3 months. Indeed, the plan is to send up to four astronauts to the Gateway for no more than 90 days a year.

Two birds, one stone; two eggs, one basket

Originally, NASA wanted to launch the PPE and HALO modules – together representing the absolute bare minimum needed to build a functional Gateway – on separate commercial rockets in 2022 and 2023, respectively. Now, according to NASA associate administrator Doug Loverro, the space agency has made the decision to launch both modules simultaneously on the same commercial rocket.

In the next year or two, two new commercial rockets with spacious payload fairings (ULA’s Vulcan and Blue Origin’s New Glenn) could debut. A third, SpaceX’s Falcon 9 and Heavy rockets, will likely launch for the first time with a new extended payload fairing within the next 12-18 months. (Teslarati – ULA/NGIS/Blue Origin/SpaceX)

This decision was made in large part because it makes sense from a technical simplicity and overall efficiency standpoint but also because several commercial launch vehicles – either currently operational or soon to be – are set to debut extremely large payload fairings. As a combined payload, the Gateway PPE and HALO modules would be too big for just about any existing launch vehicle, while the tiny handful it might fit in lack the performance needed to send such a heavy payload to the Moon.

Falcon Heavy apparently has the performance needed, as NASA used the rocket and a new stretched fairing developed by SpaceX for military customers as a baseline to determine whether PPE and HALO could launch together. Given that NASA could have technically used any of the vehicles expected to have large payload fairings for that analysis, the explicit use and mention of Falcon Heavy rather strongly suggests that the SpaceX rocket is a front runner for the new combined launch contract. This isn’t exactly surprising, given that the massive rocket has already completed three successful launches and will attempt at least another four missions between now and 2023.

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Even with its stretched fairing, Falcon Heavy’s fairing volume will still be dwarfed by Blue Origin’s New Glenn rocket. (Blue Origin)

Of the other launch vehicles expected to feature large fairings capable of supporting the combined PPE/HALO payload, ULA’s Vulcan Centaur rocket is scheduled to launch for the first time in July 2021, while Blue Origin’s New Glenn is unlikely to launch before late 2021. Northrop Grumman is also developing the Omega rocket with a large fairing, although it’s unlikely to have the performance needed for the unique Gateway payload. As such, by 2023, Falcon Heavy will almost certainly have a record of launches well out of reach of other prospective PPE/HALO launch competitors. For obvious reasons, putting both modules of a space station on a single launch raises the stakes, making it more critical than ever than risk be reduced where it can be – especially important for launch operations.

Notionally including Gateway’s PPE and HALO, Falcon Heavy now has as many as nine launches on contract (or nearly so) over the next five or so years. It’s extraordinarily unlikely that any of Falcon Heavy’s prospective competitors will be able to get close to the SpaceX rocket’s flight history by 2023, effectively making Falcon Heavy the de facto choice for NASA from an apolitical, technical perspective.

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’s Roadster appearance at SpaceX has merger watchers talking

Tesla’s next generation Roadster was spotted at SpaceX’s Hawthorne headquarters, two weeks after its unveiling.

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The Roadster’s rear wing, one of the aerodynamic elements Tesla pairs with a fan-based downforce system. (Image: Tesla)

Tesla’s next generation Roadster turned up at SpaceX’s headquarters in Hawthorne, California on Wednesday, less than two weeks after the car flew off a ramp at its unveiling in Texas.

Photos shared on X by SpaceX Engineer (@DeannaRiceSPCX) show the new Roadster parked outdoors beside the famed Falcon 9 that stands outside company headquarters at the corner of Crenshaw Boulevard and Jack Northrop Avenue. Rocket B1019 was the first orbital-class booster ever to land after a launch on December 21, 2015 after it sent 11 Orbcomm satellites to orbit and then flew back to Landing Zone 1 at Cape Canaveral, which would be the first landing in what became SpaceX’s reusable rocket program. SpaceX chose not to fly it again. After a test fire in Florida, the booster was shipped to Hawthorne and raised upright as a permanent monument in August 2016, as Teslarati reported at the time. Putting the Roadster, which flies on SpaceX cold gas thrusters, next to the rocket that started SpaceX’s landings is symbolic in itself.

The Thrust and Rocket versions of the Roadster use cold gas thrusters fed by composite overwrapped pressure vessels, the same type of tank SpaceX flies on Falcon 9, and Elon Musk described the car as the work of Tesla and SpaceX engineers working together. Tesla lists 0 to 60 mph in under 0.9 seconds for Thrust and under 0.59 seconds for Rocket, while the base Performance model relies on a fan and ground sealing system for grip, as Teslarati detailed in its breakdown of the three Roadster configurations.

Tesla has kept the car in the spotlight since the October 15 event near Waco. Last week, the company posted a video of the Roadster’s fighter jet inspired cockpit, including a Track Mode screen with a “Thruster · 5,500 PSI” readout, which we covered in our look at the Roadster’s center display. Musk also said owners will be able to ask the car to perform the stunts autonomously, and promised a looping track at Tesla’s Texas headquarters.

The visit comes as special committees at Tesla and SpaceX weigh a possible merger, a step Musk confirmed on SpaceX’s third quarter earnings call. The Roadster, built on SpaceX hardware, has become one of the clearest examples of the two companies already building products together.

Musk said at the unveiling that Roadster production will begin in 2028. Reservations are open with a $50,000 payment, Thrust is listed as a limited release and Rocket is invite only. Tesla says the car is not approved for public road use.

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Verizon, AT&T and T-Mobile are trying to shut Starlink out before FCC vote

AT&T, Verizon and T-Mobile want 290 MHz cut from an FCC satellite plan before Thursday.

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Starlink D2D direct to device vs Verizon, AT&T (Concept render by Grok)

AT&T, Verizon and T-Mobile are asking the Federal Communications Commission to pull nearly 300 MHz of spectrum out of a proposal that would let satellite companies like SpaceX offer cell service directly to ordinary phones. The request lands one day before the agency votes on it.

The FCC will vote Thursday, October 29, on a notice of proposed rulemaking that would make an additional 482 MHz available for direct to device service, expanding the number of eligible bands from five to 13, according to the FCC fact sheet. It would also scrap the rule requiring a satellite operator to lease spectrum from carriers, replacing it with a certification that the operator has coexistence agreements in place or holds the terrestrial license itself.

That second path matters for SpaceX. As Teslarati reported earlier this month, SpaceX agreed to buy Grain Management’s nationwide 800 MHz portfolio to turn Starlink Mobile into a full US carrier, adding to the spectrum it already bought from EchoStar.

The carriers want two bands removed, 2.5 GHz and 3.45 GHz, which make up 290 MHz of the 482 MHz on the table. Through industry group CTIA, they argued that about 300 million users depend on those bands and that satellite operations in them are not technically feasible. T-Mobile, which calls 2.5 GHz the foundation of its Ultra Capacity 5G network, said in its own filing that satellite interference could wipe out up to 96% of a cell site’s uplink coverage area and cut uplink speeds by 88% to 99%.

Executives from all three carriers met with FCC staff on October 20, and T-Mobile CEO Srini Gopalan met separately with FCC Chairman Brendan Carr. T-Mobile’s role stands out because it is still SpaceX’s US launch partner for Starlink Mobile. The three carriers have also teamed up on their own satellite joint venture to pool spectrum, a move widely seen as a response to Starlink.

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SpaceX is asking for the opposite. In an October 23 filing after meetings with FCC staff and commissioners’ offices, the company asked regulators to add the 902 to 928 MHz band to the proposal. “Doing so now saves time later,” SpaceX wrote. The company also asked the FCC to modernize interference rules and align satellite deployment requirements with those for terrestrial cell networks, saying the goal is to let satellite and ground networks work together so Americans stay connected wherever they are.

The carriers have not been shy about how they view SpaceX as a competitor. On Verizon’s third quarter earnings call Monday, its chief executive said Starlink Mobile “just can’t compete with a terrestrial network” and estimated SpaceX would need four to six years and $300 billion to $500 billion to build a full US carrier network.

Thursday’s vote will not settle which bands survive. Adopting the notice opens a public comment period, with final rules to come later in the proceeding. The FCC already considered and rejected 2.5 GHz for satellite coverage once, in 2024. SpaceX also is not the only satellite player watching: the FCC approved Amazon’s $11.6 billion acquisition of Globalstar on October 27, giving its planned direct to device fleet its own mobile satellite spectrum.

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Tesla Semi catches fire in California: what we know

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Credit: KTVU

A Tesla Semi caught fire in Hayward, California, which caused both directions of traffic to shut down for hours before being completely reopened early on Wednesday, the California Highway Patrol said.

The fire occurred just after 5:30 local time in Hayward on Tuesday, as the Semi caught fire in the southbound lanes of I-880 before CHP officials made the decision to shut down both lanes of traffic due to potential risks from hazardous chemical smoke.

There were no injuries reported.

The cause of the fire is currently unknown, as neither Tesla nor the CHP have not determined a cause.

However, some images taken before the Semi was completely destroyed by the fire seem to indicate this might have been an older unit, as it appears to be one of the designs that Tesla shipped as part of its pilot program, before revising it and starting mass production just a month ago.

At the time of publication, CHP had not returned our request for a comment for additional details, including the Semi involved and any potential collaboration on an investigation between the CHP and Tesla. We will update this story when we hear back from them.

The southbound lanes were reopened at 3:30 a.m. on Wednesday, with the northbound lanes opening last night a few hours after the fire began. The CHP did state that the lithium batteries were “incredibly difficult to extinguish,” according to NBC Bay Area.

The truck’s driver said that the Semi caught fire, but he did not have an explanation.

An estimated 5,000 to 7,000 semi-truck and large commercial vehicle fires occur on U.S. roadways every year.

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