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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 Robotaxi’s biggest rival sends latest statement with big expansion

The new expanded geofence now covers a broader region of Austin and its metropolitan areas, extended south to Manchaca and north beyond US-183.

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Credit: @AdanGuajardo/X

Tesla Robotaxi’s biggest rival sent its latest statement earlier this month by making a big expansion to its geofence, pushing the limits up by over 50 percent and nearing Tesla’s size.

Waymo announced earlier this month that it was expanding its geofence in Austin by slightly over 50 percent, now servicing an area of 140 square miles, over the previous 90 square miles that it has been operating in since July 2025.

Tesla CEO Elon Musk shades Waymo: ‘Never really had a chance’

The new expanded geofence now covers a broader region of Austin and its metropolitan areas, extended south to Manchaca and north beyond US-183.

These rides are fully driverless, which sets them apart from Tesla slightly. Tesla operates its Robotaxi program in Austin with a Safety Monitor in the passenger’s seat on local roads and in the driver’s seat for highway routes.

It has also tested fully driverless Robotaxi services internally in recent weeks, hoping to remove Safety Monitors in the near future, after hoping to do so by the end of 2025.

Although Waymo’s geofence has expanded considerably, it still falls short of Tesla’s by roughly 31 square miles, as the company’s expansion back in late 2025 put it up to roughly 171 square miles.

There are several differences between the two operations apart from the size of the geofence and the fact that Waymo is able to operate autonomously.

Waymo emphasizes mature, fully autonomous operations in a denser but smaller area, while Tesla focuses on more extensive coverage and fleet scaling potential, especially with the potential release of Cybercab and a recently reached milestone of 200 Robotaxis in its fleet across Austin and the Bay Area.

However, the two companies are striving to achieve the same goal, which is expanding the availability of driverless ride-sharing options across the United States, starting with large cities like Austin and the San Francisco Bay Area. Waymo also operates in other cities, like Las Vegas, Los Angeles, Orlando, Phoenix, and Atlanta, among others.

Tesla is working to expand to more cities as well, and is hoping to launch in Miami, Houston, Phoenix, Las Vegas, and Dallas.

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Tesla automotive will be forgotten, but not in a bad way: investor

It’s no secret that Tesla’s automotive division has been its shining star for some time. For years, analysts and investors have focused on the next big project or vehicle release, quarterly delivery frames, and progress in self-driving cars. These have been the big categories of focus, but that will all change soon.

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(Credit: Tesla)

Entrepreneur and Angel investor Jason Calacanis believes that Tesla will one day be only a shade of how it is recognized now, as its automotive side will essentially be forgotten, but not in a bad way.

It’s no secret that Tesla’s automotive division has been its shining star for some time. For years, analysts and investors have focused on the next big project or vehicle release, quarterly delivery frames, and progress in self-driving cars. These have been the big categories of focus, but that will all change soon.

I subscribed to Tesla Full Self-Driving after four free months: here’s why

Eventually, and even now, the focus has been on real-world AI and Robotics, both through the Full Self-Driving and autonomy projects that Tesla has been working on, as well as the Optimus program, which is what Calacanis believes will be the big disruptor of the company’s automotive division.

On the All-In podcast, Calcanis revealed he had visited Tesla’s Optimus lab earlier this month, where he was able to review the Optimus Gen 3 prototype and watch teams of engineers chip away at developing what CEO Elon Musk has said will be the big product that will drive the company even further into the next few decades.

Calacanis said:

“Nobody will remember that Tesla ever made a car. They will only remember the Optimus.”

He added that Musk “is going to make a billion of those.”

Musk has stated this point himself, too. He at one point said that he predicted that “Optimus will be the biggest product of all-time by far. Nothing will even be close. I think it’ll be 10 times bigger than the next biggest product ever made.”

He has also indicated that he believes 80 percent of Tesla’s value will be Optimus.

Optimus aims to totally revolutionize the way people live, and Musk has said that working will be optional due to its presence. Tesla’s hopes for Optimus truly show a crystal clear image of the future and what could be possible with humanoid robots and AI.

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Tesla Robotaxi fleet reaches new milestone that should expel common complaint

There have been many complaints in the eight months that the Robotaxi program has been active about ride availability, with many stating that they have been confronted with excessive wait times for a ride, as the fleet was very small at the beginning of its operation.

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Credit: Tesla

Tesla Robotaxi is active in both the Bay Area of California and Austin, Texas, and the fleet has reached a new milestone that should expel a common complaint: lack of availability.

It has now been confirmed by Robotaxi Tracker that the fleet of Tesla’s ride-sharing vehicles has reached 200, with 158 of those being available in the Bay Area and 42 more in Austin. Despite the program first launching in Texas, the company has more vehicles available in California.

The California area of operation is much larger than it is in Texas, and the vehicle fleet is larger because Tesla operates it differently; Safety Monitors sit in the driver’s seat in California while FSD navigates. In Texas, Safety Monitors sit in the passenger’s seat, but will switch seats when routing takes them on the highway.

Tesla has also started testing rides without any Safety Monitors internally.

Tesla Robotaxi goes driverless as Musk confirms Safety Monitor removal testing

This new milestone confronts a common complaint of Robotaxi riders in Austin and the Bay, which is vehicle availability.

There have been many complaints in the eight months that the Robotaxi program has been active about ride availability, with many stating that they have been confronted with excessive wait times for a ride, as the fleet was very small at the beginning of its operation.

With that being said, there have been some who have said wait times have improved significantly, especially in the Bay, where the fleet is much larger.

Tesla’s approach to the Robotaxi fleet has been to prioritize safety while also gathering its footing as a ride-hailing platform.

Of course, there have been and still will be growing pains, but overall, things have gone smoothly, as there have been no major incidents that would derail the company’s ability to continue developing an effective mode of transportation for people in various cities in the U.S.

Tesla plans to expand Robotaxi to more cities this year, including Miami, Las Vegas, and Houston, among several others.

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