Connect with us

News

SpaceX's Falcon rockets might need a giant tower on wheels for US military launches

In order to shore up a potentially lucrative USAF contract, SpaceX has plans to build a massive mobile tower at its Pad 39A launch facilities. (Pauline Acalin)

Published

on

SpaceX reportedly plans to build a massive mobile gantry – effectively a tower on wheels – at one of its two Florida launch pads, a bid to meet obscure military launch criteria needed to secure highly lucrative Falcon 9 and Falcon Heavy launch contracts from the US government.

Although this is not the first time that SpaceX and vertical integration have been thrown around in the same sentence, it is the first time that the company is reportedly close to actually finalizing its plans along those lines and constructing a real solution at one or more of its three orbital-class launch pads.

Throughout the entirety of its active launch operations, SpaceX has relied exclusively on horizontal integration for its Falcon 1, 9, and Heavy rockets and the satellites they launch. CEO Elon Musk and other executives have maintained a consistent rationale for that preference over the years: ensuring that rockets and payloads can be horizontally integrated is the best possible solution so long as SpaceX’s primary motivation is improving access to space and lowering the cost of launch. As such, SpaceX has one and only one major motivation to jerry-rig a vertical integration solution for its Falcon family of rockets: necessity by way of arcane US military launch contract requirements.

Spaceflight Now broke the latest news first on January 3rd, 2020, revealing that SpaceX was at long last taking a substantial step towards actually building its own vertical integration infrastructure at Kennedy Space Center (KSC) Launch Complex 39A – a step that was long anticipated but has taken years to transpire into anything concrete. The gist is this: for a variety of seemingly shoehorned and far-from-obvious reasons, the secretive, ultra-expensive spy satellites that contractors like Lockheed Martin and Boeing build for the US Air Force (USAF) and the National Reconnaissance Office (NRO) builds itself are designed in such a way that they apparently cannot be flipped horizontally in a rocket’s payload fairing.

Although taken from Blue Origin’s New Glenn payload user’s guide, SpaceX’s process of encapsulating satellites in Falcon payload fairings is functionally identical. (Blue Origin)

Identical to the process depicted above for Blue Origin’s in-development New Glenn rocket, up to now, SpaceX has encapsulated all satellite payloads vertically, sealed the payload fairing, rotated that integrated fairing and payload, and then attached that assembly to horizontal Falcon 9 and Falcon Heavy rockets. The rocket is then transported to the launch pad on a transporter erector (T/E), which – as the name suggests – raises the rocket and payload vertical before propellant loading and launch.

For certain USAF and NRO launch contracts, breakover (horizontal flip) is unacceptable and their preference is that the launch vehicle be brought vertical before the payload – also still vertical – is stacked on top. While it sounds simple in principle (i.e. “Just stick a crane out by the pad!”), vertical payload integration is exceptionally tedious unless you already have the infrastructure in place. Competitor United Launch Alliance (ULA), for example, already has that infrastructure – having held a decade-long monopoly over US military launches that only ended 5-7 years ago, depending on how it’s measured.

Advertisement

Both ULA’s Atlas V, Delta IV, and soon-to-be Vulcan Centaur rockets and the infrastructure used to launch them have all been designed around vertical payload integration – essentially requiring massive, expensive, and complicated buildings-on-wheels at each launch facility.

(Tom Cross)
In effect, SpaceX must partially copy competitor United Launch Alliance (ULA) by building its own massive service tower to evenly compete with the company on the latest lucrative US Air Force launch contract.

Per Spaceflight Now, SpaceX has plans to build a similar mobile tower at Pad 39A, currently dedicated Falcon 9/Crew Dragon missions for NASA and the occasional Falcon Heavy launch. That tower will ultimately roll up to Falcon 9 or Heavy rockets on the pad, fully covering the vehicles and giving technicians an array of work platforms and tools to support vertical payload integration, among other uses. SFN says that the mobile tower will be even taller than the existing Fixed Service Structure (FSS) tower at Pad 39A, measuring some 30 stories (100m/330ft) tall.

In line with a recent FSS redesign that saw that existing tower modified for Crew Dragon and outfitted with semi-transparent black glass or plastic and a black-and-white color scheme, the new mobile tower will apparently be built with a similar design language.

While now outdated, SpaceX’s 2016 Mars rocket featured a giant crane used for vertical integration. BFR appears to use the same approach. (SpaceX)

Ultimately, all of SpaceX’s plans for Starship – a massive next-generation, fully-reusable rocket – have relied on some form of vertical integration for Super Heavy boosters, Starships, and tankers. In a best-case scenario, all of those vehicles may one day land in reach of a giant crane situated at the launch pad, allowing SpaceX to lift them back to the pad and install ships and tankers on Super Heavy boosters just hours (maybe even minutes) after touchdown – truly rapid reuse.

For now, it’s unclear when exactly SpaceX wants to start cutting metal for its new Falcon 9/Heavy gantry, but it’s safe to say the company will move fast as usual once it begins.

Check out Teslarati’s Marketplace! We offer Tesla accessories, including for the Tesla Cybertruck and Tesla Model 3.

Advertisement

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.

Advertisement
Comments

Elon Musk

Elon Musk teases Tesla Optimus Gen 3 capabilities: ‘So many improvements’

If you thought Optimus Gen 2 was impressive, Tesla might have a surprise for you.

Published

on

Credit: Tesla Optimus | X

Elon Musk has teased that huge improvements are coming to Tesla’s Optimus humanoid robot, which is arguably the product that the company is developing with the most potential for everyday use by consumers and valuation increases from a financial perspective.

Optimus is still in the development stages, but Tesla has made great strides in its development over the past several years. It started as a simple idea that was unveiled with a human being in a spandex suit.

Tesla posts Optimus’ most impressive video demonstration yet

Just a few years later, Tesla has developed several humanoid robot prototypes that have made their way to influencers and have lent a helping hand around the company’s manufacturing facilities.

Tesla has already introduced two generations of Optimus, as the most recent release featured a vast number of improvements from the initial version.

The following is a list of things Tesla improved upon with Optimus Gen 2 compared to Gen 1:

  • Tesla introduced a weight reduction of roughly 22 pounds, improving efficiency and agility
  • Optimus Gen 2 had a walking speed that improved by 30 percent over Gen 1
  • Tesla developed more capable hands that had 22 degrees of freedom, double that of Gen 1. This improved object handling
  • Optimus Gen 2 had a 2-degree-of-freedom neck, as Gen 1’s was fixed
  • Tesla integrated actuators and sensors for better performance. This includes things like foot force/torque sensing, articulated toe sections that are close to human foot geometry for better balance and movement
  • Optimus Gen 2 has 28 degrees of overall freedom, improving flexibility from the first generation
  • Tesla’s Optimus Gen 2 can do more than Gen 1, and has shown improved motor control and precision, doing things like squats, yoga poses, dancing, and even poaching an egg

These changes essentially brought Tesla closer to what will be the Optimus version that makes it to production. The company has plans to start production for the public in 2026, but some units will be manufactured for internal use within its factories as soon as this year. Tesla has said it could scale to 100,000 units or more by next year.

Musk also revealed to Teslarati recently that the company is in the process of building the production line that will bring manufacturing rates of Optimus to that level.

However, there is another design of Optimus coming, and Musk says it will feature “so many improvements”:

Tesla has said that Optimus will have the capability to perform tedious and time-consuming tasks like folding laundry, babysitting, cooking, walking the dog, and plenty of other things. However, it will be super impressive to see it do things that require true coordination, like threading a needle, for example.

Musk did not hint toward any specific developments that Tesla will aim for with Optimus Gen 3, but the sky is the limit, especially as it will be performing some manufacturing tasks across its factories.

Continue Reading

Elon Musk

Elon Musk slams Bloomberg’s shocking xAI cash burn claims

Musk stated that “Bloomberg is talking nonsense.”

Published

on

Credit: xAI/X

Elon Musk has forcefully rejected Bloomberg News’ claims that his artificial intelligence startup, xAI, is hemorrhaging $1 billion monthly. 

In a post on X, Musk stated that “Bloomberg is talking nonsense.” He also acknowledged an X user’s comment that people “really have no idea what’s at stake” with AI.

Bloomberg‘s Allegations and Musk’s Rebuttal

The Bloomberg News report painted a dire picture of xAI’s finances. Citing people reportedly familiar with the matter, the news outlet claimed that xAI burns $1 billion a month as costs for building advanced AI models outpaced the company’s limited revenues. 

Bloomberg alleged that xAI is planning to spend over half of a proposed $9.3 billion fundraising haul in three months, with a projected $13 billion loss in 2025. The report also claimed that of the $14 billion that xAI has raised since 2023, only $4 billion remained by Q1 2025. Even this amount, the news outlet alleged, will be nearly depleted in Q2.

xAI did not comment on Bloomberg‘s claims, though Elon Musk shared his thoughts on the matter on social media platform X. In response to an X user who quoted the publication’s article, Musk noted that “Bloomberg is talking nonsense.” Musk, however, did not provide further details as to why the publication’s report was fallacious.

Advertisement

xAI’s Bright Horizon

Despite Bloomberg‘s claims, even the publication noted that xAI’s prospects are promising. The company, now merged with X, aims to leverage the platform’s vast data archives for model training, which could reduce costs compared to rivals like OpenAI. Tapping into X also allows xAI to access real-time information from users across the globe. 

xAI’s valuation reportedly soared to $80 billion by Q1 2025, up from $51 billion in 2024. The AI startup has attracted heavyweight investors such as Andreessen Horowitz, Sequoia Capital, and VY Capital so far, and optimistic projections point to profitability possibly being attained by 2027. This would be quite a feat for xAI as OpenAI, the AI startup’s biggest rival, is still looking at 2029 as the year it could become cash flow positive.

Continue Reading

Elon Musk

xAI supercomputer faces lawsuit over air pollution concerns

NAACP & environmental groups are suing Elon Musk’s xAI over turbine emissions at its Colossus supercomputer site.

Published

on

xAI-supercomputer-memphis-environment-pushback
(Credit: xAI)

The xAI supercomputer, Colossus, faces a potential lawsuit from the NAACP and the Southern Environmental Law Center over pollution concerns tied to its gas-powered turbines. The facility has sparked debate over its environmental impact versus economic benefits.

The xAI data center has been operational since last year. The company used pollution-emitting turbines without an air permit, citing a 364-day exemption. Southern Environmental Law Center attorney Patrick Anderson disputed xAI’s exemption, stating: “there is no such exemption for turbines — and that regardless, it has now been more than 364 days.”

The groups issued a 60-day notice of intent to sue under the Clean Air Act, challenging xAI’s permit application under review by the Shelby County Health Department.

According to AP, critics argue the turbines emit smog, carbon dioxide, nitrogen oxides, and formaldehyde, worsening health risks in an area with cancer rates four times the national average.

Advertisement

“The permit itself says emissions from the site ‘will be an area source for hazardous air pollutants,’” the Southern Environmental Law Center noted, alleging Clean Air Act violations.

Opponents claim xAI installed up to 35 turbines—exceeding the 15 requested—without community oversight, straining Memphis’s power grid.

xAI responded: “The temporary power generation units are operating in compliance with all applicable laws.”

The company highlighted its economic contributions, including billions in investments, millions in taxes, and hundreds of jobs. At an April community meeting, xAI’s Brent Mayo underscored that the “tax revenue will support vital programs like public safety, health, human services, education, firefighters, police, parks, and so much more.” He projected that xAI would generate over $100 million in tax revenue by next year. The company is also investing $35 million in a power substation and $80 million in a water recycling plant.

Additionally, xAI is transitioning to sustainable power, particularly Tesla Megapacks. It is actively working on demobilizing the gas turbines.

Advertisement

“The temporary natural gas turbines that were being used to power the [xAI’s] Phase I GPUs prior to grid connection are now being demobilized and will be removed from the site over the next two months,” shared the Greater Memphis Chamber. xAI brought Tesla Megapack batteries and a 150-megawatt substation online earlier this year.

Despite xAI’s expansion to a second 1-million-square-foot site, the lawsuit threat underscores tensions between innovation and environmental justice.

Continue Reading

Trending