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SpaceX Falcon Heavy rocket rolls to pad for Tuesday launch, dual booster landing

A Falcon Heavy rocket has rolled out to the launch pad - to launch - for the first time since June 2019. (Richard Angle)

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A SpaceX Falcon Heavy rocket has rolled out to Kennedy Space Center Pad 39A for its first launch (and dual booster landing) in almost three and a half years.

Missing its payload fairing and the US Space Force’s classified USSF-44 payload, SpaceX’s fourth Falcon Heavy rocket rolled out to Pad 39A for the first time on October 25th. On the 27th, the rocket successfully fired up all 27 of its first-stage Merlin 1D engines, reasserting its status as the most powerful operational rocket in the world. On October 30th, SpaceX finally brought Falcon Heavy horizontal and rolled the rocket back to Pad 39A’s integration hangar, where the USSF-44 mission’s several payloads – safely stowed inside a payload fairing – were installed on the rocket.

24 hours later, Falcon Heavy – now fully assembled – departed the hangar again. According to the US Space Systems Command (SSC), despite the exceptionally late rollout on October 31st, SpaceX is on track to launch Falcon Heavy no earlier than (NET) 9:41 am EDT (13:41 UTC) on Tuesday, November 1st.

As previously discussed on Teslarati, USSF-44 will be SpaceX’s first attempt at a direct launch to a geostationary orbit (GEO) some ~36,000 kilometers (~22,400 mi) above Earth’s surface, where spacecraft can hover motionless over their region of choice. To accomplish that feat, Falcon Heavy’s upper stage will need to survive a roughly six-hour coast in the harsh vacuum of space, likely making USSF-44 one of the most challenging missions SpaceX has ever attempted.

Long orbital coasts of six or so hours are necessary for some of the most challenging launch trajectories. Direct-to-geostationary launches are the most common mission requiring long coast capabilities and are often demanded by the US military. When Falcon’s upper stage gets too cold, its kerosene fuel – which freezes at a much higher temperature than Falcon’s liquid oxygen oxidizer – becomes viscous and slush-like before it becomes solid. If ingested in Falcon’s Merlin Vacuum engine, slushy fuel would likely prevent ignition or outright destroy it.

Teslarati.com – October 10th, 2022

Simultaneously, while worrying about kerosene fuel getting too cold, SpaceX must also ensure that the Falcon upper stage’s cryogenic liquid oxygen (LOx) oxidizer doesn’t boil into gas. If too much LOx warms up and has to be vented out as it turns to gas, the Falcon upper stage could find itself without enough propellant to complete its geostationary orbit circularization burn.

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LOx is far less stable, which makes it a bit ironic that the upper stage’s fuel tank bares the only visible sign of the tweaks needed to survive a long coast. To keep the RP1 fuel warmer in orbit, SpaceX has added a layer of grey paint to the RP1 tank, increasing the amount of heat that can be absorbed through unfiltered sunlight. The uninsulated LOx tank, meanwhile, benefits from the unintuitive fact that a cryogenic liquid can stay liquid for a surprisingly long time because some of it warms up and boils off as a gas, sacrificing a small quantity to keep the rest cool.

A look inside the LOx tank of a Falcon 9 upper stage while in orbit. (SpaceX)

According to the US Space Force, USSF-44 will carry several “various payloads” attached to the second Northrop Grumman “Long Duration Propulsive EELV (Evolved Expendable Launch Vehicle) Secondary Payload Adapter” or LDPE-2 – essentially a long-duration kick stage. Cataloged on EverydayAstronaut.com, the payloads include two Lockheed Martin LINUSS-A cubesats that will demonstrate a handful of new technologies and capabilities; TETRA-1, a microsat built by Millenium Space Systems to test on-orbit maneuverability; and a communications satellite prototype called USUVL. Spaceflight Now reports that LPDE-2 will carry three hosted payloads and deploy three satellites.

Finally, a recent Space Systems Command press release [PDF] mentioned a mysterious “Shepard demonstration” – likely a second propulsive kick stage – for the first time, which almost nothing is known about. It’s unclear if there is a main classified satellite the mission revolves around or if USSF-44 is simply a collection of various rideshare payloads headed to GEO.

Regardless, to launch them directly into geostationary orbit, USSF-44 will mark the first time SpaceX intentionally expends a Falcon Heavy booster. Over three previous launches, SpaceX only managed to land a Falcon Heavy center core once, but that core then tipped over and was destroyed at sea. Two other attempts resulted in failed landings. USSF-44 will continue that trend. Falcon Heavy’s twin side boosters will attempt to continue a more positive trend of simultaneous side-by-side landings and boost back to Florida to touch down at SpaceX’s LZ-1 and LZ-2 pads. SpaceX will also attempt to recover both halves of Falcon Heavy’s payload fairing a record-breaking 1410 kilometers (876 mi) off the Florida coast.

SpaceX says weather is 90% favorable for Falcon Heavy’s November 1st launch attempt. Stay tuned for a link to the company’s official webcast.

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’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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Investor's Corner

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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