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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)

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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.

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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.

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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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Tesla vandal who lit Las Vegas repair center on fire arrested

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A vandal in Las Vegas who lit a Tesla repair center on fire has been arrested, bringing a name and face to the crime that engulfed vehicles and a structure in flames.

Officers in Las Vegas arrested Paul Kim, a 36-year-old, on Wednesday. He faces charges of arson and possessing an explosive device.

The Tesla repair center at 6260 West Badura Avenue was set aflame on March 18 at around 2:45 a.m. In total, five vehicles were set on fire, as well as the building itself. It was one of the more notable instances of vandalism against Tesla in recent months, but police now have their culprit.

Las Vegas Metro Police Department Sheriff Dori Koren described the weapons Kim used to execute the attack:

“He used what appeared to be multiple Molotov cocktails and firearms to conduct his attack.”

As the instances of attacks on Tesla continue to be publicized, we are now seeing considerable pushback from owners, the company, and even the United States government regarding what it calls “domestic terrorism.”

Owners are now filing lawsuits against those who vandalize their vehicles, as the first civil suit against a vandal was filed in Texas yesterday.

Tesla has not made any moves itself against the vandals, but we expect the company to potentially enter some litigation against groups or politicians that incite violence against its property and the owners of its vehicles.

Additionally, the U.S. government has utilized the FBI to probe incidents against Tesla as a part of them being constituted as instances of domestic terrorism. Earlier this month, the Bureau established a specific task force to handle Tesla-related attacks.

“The FBI has been investigating the increase in violent activity toward Tesla, and over the last few days, we have taken additional steps to crack down and coordinate our response,” FBI head Kash Patel said on X. “This is domestic terrorism. Those responsible will be pursued, caught, and brought to justice.”

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Elon Musk clarifies Trump tariff effect on Tesla: “The cost impact is not trivial”

The U.S. President has stated that Elon Musk stayed silent and provided no input in the administration’s tariffs.

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MINISTÉRIO DAS COMUNICAÇÕES, CC BY 2.0 , via Wikimedia Commons

U.S. President Donald Trump’s plan to implement a 25% tariff on non-U.S.-made vehicles starting next week would affect American electric car maker Tesla. 

This was confirmed by CEO Elon Musk in a recent post on social media platform X.

Musk and Trump

While Elon Musk works closely with the Trump administration due to his role in the Department of Government Efficiency (DOGE), the U.S. president has emphasized that the Tesla CEO never asks for favors. This was highlighted in his recent comments, when he stated that Elon Musk stayed silent and provided no input in the administration’s 25% auto tariffs.

When asked by reporters if the new tariffs would be good for Tesla, Trump noted that they may be “net neutral or they may be good.” The U.S. president also pointed to Tesla’s automotive plants in Fremont, California and Austin, Texas, which produce vehicles that are sold in the country. “Anybody that has plants in the United States — it’s going to be good for them,” Trump noted.

Tesla Affected

In a post on X, Elon Musk clarified that the Trump administration’s tariffs would affect the prices of vehicle parts that are sourced from other countries. This was a concern that Tesla previously outlined in a letter to the U.S. Trade Representative, which noted that even with “aggressive localization” of its supply chain, “certain parts and components are difficult or impossible to source within the United States.”

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As per Musk in his recent post on X, the cost impact of the Trump administration’s tariffs is no joke. “To be clear, this will affect the price of parts in Tesla cars that come from other countries. The cost impact is not trivial,” Musk wrote in his post.

Potential Effects

Reactions to Musk’s comments from users of the social media platform were varied, with some speculating that the Trump auto tariffs could result in Teslas becoming more expensive in the United States. Despite this, the potential increases in Tesla’s vehicle prices might not be as notable as other cars, particularly those that are produced outside the country.

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Hyundai’s $7.6B Georgia plant dodges Trump’s 25% Tariffs  

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Hyundai-Georgia-plant-vs-trump-tariffs
(Credit: Hyundai USA)

Hyundai’s $7.6 billion Georgia plant dodged U.S. President Donald Trump’s recently announced tariffs on imported vehicles and auto parts.

The South Korean automaker’s Hyundai Motor Group Metaplant America (HMGMA) in Georgia celebrated its opening recently by announcing plans to expand the factory. Hyundai aims to boost production by two-thirds, increasing HMGMA’s capacity from 300,000 to 500,000 vehicles annually.

“This plant couldn’t come at a better time than now. Because definitely all the cars that we would produce here are going to be exempted from any tariffs,” said Hyundai Motor Company CEO Jose Munoz.

President Donald Trump recently announced 25% tariffs on auto imports at the White House. President Trump praised the HMGMA plan in Georgia, commenting it was a “clear demonstration that tariffs very strongly work.”

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According to the Associated Press, the Georgia expansion ties into $21 billion in U.S. investments. It includes a $5.8 billion steel mill in Louisiana, which will supply parts for Georgia and Alabama plants.

Hyundai aims to employ 8,500 workers at the Bryan County site. Battery partners are estimated to add 3,500 more jobs. The car company does not have worker estimates for HMGMA’s expansion plans.

Hyundai Motor Group Executive Chairman Euisun Chung said the legacy automaker came to Georgia “to stay, to invest and to grow.”

“Standing here today, I can say I have never been more confident about building the future of mobility with America, in America,” Chung said.

Hyundai started EV production in Georgia six months ago. As of this writing, over 1,200 workers run the massive plant. Hyundai’s Georgia factory builds two electric SUVs now. The IONIQ 5 is already in production. Hyundai will start producing the IONIQ 9 this spring. Hyundai plans to produce hybrids, too. Munoz predicted hybrids would eventually make up one-third of production.

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