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SpaceX’s first Falcon 9 Block 5 booster casualty battered but still intact in aerial photos

While battered and wounded, Falcon 9 B1050 is intact and (mostly) in one piece. (Tom Cross)

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Shortly after successfully sending a reused Cargo Dragon spacecraft on its way towards the International Space Station (ISS), SpaceX Falcon 9 Block 5 booster B1050 experienced an anomaly with its grid fins during a planned landing, resulting in a shockingly soft (but unintentional) landing just off the Florida coast.

By some minor miracle, the drastically off-nominal loads experienced by the booster during its unintended departure from controlled flight somehow did not rise to the bar of structural failure. Nevertheless, now floating a handful of miles east of Port Canaveral’s mouth, B1050 did not make it through the ordeal unscathed.

https://twitter.com/_TomCross_/status/1070742919986991107

A little more than 24 hours after the booster found itself floating sideways in the Atlantic Ocean, B1050 had floated a solid ten miles south of its original position into waters and airspace that no longer fell under the purview of Cape Canaveral Air Force Station, technically a military outpost. As the captains of tugboat Eagle and SpaceX support vessel GO Quest discussed the logistics of returning the booster to port with the local harbormaster and US Coast Guard, Teslarati photographer Tom Cross chartered a local helicopter to get a slightly better view of the waterlogged rocket and its ad-hoc recovery operations.

A casualty of war (with the air)

Second only to the fact that the booster appears to be in disproportionately good shape considering the circumstances, by far the most noteworthy feature of the newest addition to SpaceX’s marine fleet is the sheer damage suffered by B1050’s interstage, the black carbon fiber composite structure that topsFalcon 9 Block 5 boosters and hosts its grid fins and stage separation mechanism.

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Revealed from an aerial perspective, it almost looks as if one side of the composite cylinder was smashed with a giant hammer, tearing off at least 20% of the entire interstage – including one of four titanium grid fins – while leaving another large segment hanging on by only partially-figurative carbon fiber threads.

 

It’s not 100% clear why B1050’s interstage was so readily destroyed but a narrative can certainly be drawn from the current public record. After its grid fins lost hydraulic power and became stuck at an extreme angle, B1050 almost immediately lost control and began rapidly and quite brutally spinning and flailing, tossed around as it hurtled through the air at supersonic speeds. Being a predominately smooth cylinder, Falcon 9’s first stage is inherently prone to rotation in the presence of high-velocity air currents, which is why its grid fins are an absolute necessity for maintaining control authority during in-atmosphere “flights”.

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In a show that will turn the stomach of anyone familiar with a rocket’s typically narrow load tolerances, Falcon 9 B1050 experienced extreme aerodynamic stresses during the worst of its uncontrolled tumble, to the extent that the entire booster and interstage can be seen visibly twisting at least 5 degrees left and right from the perspective of an onboard camera. In the video above, focus on the center of Falcon 9’s grid fins during the first and last 5-10 seconds to properly visualize the extreme forces at play.

It might look fairly innocent to the untrained eye, but keep in mind that Falcon 9’s interstage is no more than a couple of inches thick and is absolutely massive, stretching 3.7m (~12 ft) in diameter. Perhaps even more importantly, the damage to the interstage has almost without a doubt rendered it unusable from the perspective of SpaceX’s established methods of safely moving and manipulating Falcon 9 boosters.

 

All of those methods rely on adapters that attach to the interstage to lift the rocket vertically or support part of its ~30-ton dry mass horizontally. Lacking a sound interstage, it’s now entirely unclear how SpaceX might go about getting B1050 onto land without damaging it further. In simpler terms, this bodes very, very badly for any plans to safely reuse B1050 in the near (or distant) future. After suffering loads that severely weakened and ultimately tore its interstage to pieces, it’s reasonable to assume that the rest of the rocket’s lithium-aluminum propellant tanks experienced stresses that are at least roughly comparable.

If that’s the case, perhaps the only real hope for B1050’s ‘reuse’ will be the recovery of certain subcomponents and miscellaneous parts that may have made it through the ordeal unscathed or with only minor damage. The three remaining titanium grid fins are a guaranteed recovery, while COPVs, cold gas thrusters, avionics boxes, and maybe even some of its nine Merlin 1D engines could be salvageable with some level of refurbishment.

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In the meantime, the tentative plan right now is to two B1050 into Port Canaveral sometime after dawn tomorrow, either ending up at drone ship OCISLY’s berth or another less-developed section of the port.


For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet check out our brand new LaunchPad and LandingZone newsletters!

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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SpaceX is partnering with chipmakers to enable Starlink satellite-to-cell service

President Gwynne Shotwell outlined the effort during a space industry conference in Paris.

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Credit: SpaceX/X

SpaceX is working with microchip manufacturers to integrate satellite-connectivity hardware into smartphones, advancing its plan for direct-to-device services through Starlink. 

The move follows the company’s $17 billion acquisition of wireless spectrum from EchoStar Corp., a deal that positions SpaceX to operate more independently of traditional telecom carriers. 

President Gwynne Shotwell outlined the effort during a space industry conference in Paris this week, as noted in a Bloomberg News report.

Starlink direct-to-device

Starlink currently serves millions of customers in over 100 countries, primarily through ground-based dishes. The company, however, is now expanding into satellite-to-cell service, which should enable unmodified phones to connect directly with orbiting satellites. While SpaceX has a partnership with T-Mobile US, the EchoStar spectrum purchase gives it more control to negotiate with global carriers on its own terms.

“We’re working with chip manufacturers to get the proper chips in phones,” the SpaceX President stated. “We will now be initiating discussions with telcos in a different way now. Now it’s our spectrum, but we want to work with them, almost providing capacity and wholesaling capacity to their customers.”

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The company plans to launch satellites capable of supporting its direct-to-device business within two years, with early mobile phone testing expected by late 2026.

Starship program continues test flights

Shotwell also addressed SpaceX’s Starship program, which recently completed its 10th test flight in August. She said the mission met all objectives, providing a critical morale boost to teams after a challenging development year. 

“My Starship team needed that win,” Shotwell noted. “Development programs always are kind of a 24/7 operation, and I was really pleased for them.”

SpaceX is planning to fly one more iteration of the current Starship prototype, known as V2, before transitioning to the next-generation V3 vehicle. That version, expected to debut late this year or early 2026, is designed to be more capable and support eventual crewed missions to the Moon and Mars. 

“The V3, which we want to fly hopefully late this year, but maybe early next year, is really the vehicle that could take humans to the moon and Mars,” Shotwell stated.

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U.S. Judge dismisses lawsuit against SpaceX Starship Boca Chica launch site

The ruling found that the FAA had met its obligations in reviewing the potential environmental effects of Starship launches.

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(Credit: SpaceX)

A U.S. district court judge has dismissed a lawsuit brought by conservation groups challenging the Federal Aviation Administration’s approval of SpaceX’s expanded rocket launch operations in Boca Chica, Texas. 

The ruling, issued Monday, found that the FAA had met its obligations in reviewing the potential environmental effects of Starship launches.

FAA review withstands legal challenge

The lawsuit centered on whether the FAA properly assessed the impact of SpaceX’s operations on endangered wildlife, including ocelots, jaguarundis, and Kemp’s Ridley sea turtles, as noted in a report from The Guardian. The plaintiffs argued that noise, light pollution, and construction activity degraded the surrounding habitat, which also serves as nesting grounds for threatened shorebirds.

The lawsuit cited SpaceX’s April 2023 Starship test, which destroyed its launchpad and scattered debris across a large area. The blast reportedly ignited a grassfire and damaged wildlife habitats, including a bobwhite quail nest.

Judge Carl Nichols, for his part, ruled that the FAA had satisfied its obligation“to take a hard look at the effects of light on nearby wildlife.” The decision effectively cleared a regulatory hurdle for SpaceX, which has been working to expand Starship launch activity at its Boca Chica facility.

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A continued ramp

SpaceX continues to scale its operations nationwide. Beyond Starship, the company is also seeking approval to nearly double Falcon rocket launches from Vandenberg Space Force Base in California, from 50 annually to 95. 

Former President Trump has also shared his intention to increase U.S. launch capacity, setting a target for substantial growth by 2030. Considering that SpaceX is by far the world’s dominant launch provider, Trump’s support for more launches will likely benefit the private space company.

For now, at least, the ruling should allow continued expansion at a time when Starship remains central to long-term goals such as Mars missions and NASA’s Artemis program.

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Elon Musk

SpaceX to expand Central Texas facility with $8M Bastrop project

Bastrop is already the site of several Elon Musk-led ventures.

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Credit: SpaceX

SpaceX is set to expand its presence in Central Texas with an $8 million project to enlarge its Bastrop facility, as per state filings. 

The 80,000-square-foot addition, which is scheduled to begin construction on September 24 and wrap in early January 2026, was registered with the Texas Department of Licensing and Regulation and initially reported by My San Antonio

New investment

Bastrop is already the site of several Elon Musk-led ventures. The upcoming expansion will extend SpaceX’s office at 858 FM 1209, near Starlink’s operations and The Boring Company’s facilities. Just down the road, X is housed in the Hyperloop Plaza at 865 FM 1209.

SpaceX’s expansion reflects a steady buildup of resources in Bastrop since the private space firm established its presence in the area. The addition was praised by Tesla Governor Greg Abbott, who wrote on X that the expansion will “bring more jobs, innovations and will strengthen Starlink’s impact worldwide.” 

State support

In March, Gov. Greg Abbott announced a $17.3 million state grant to SpaceX for an “expansion of their semiconductor research and development (R&D) and advanced packaging facility in Bastrop.” The project is expected to create more than 400 new jobs and generate over $280 million in capital investment.

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Following the grant award, the Texas Governor also noted that SpaceX’s facility would be growing by 1 million square feet across three years to boost its Starlink program. SpaceX’s Starlink division is among the company’s fastest-growing segments, with the satellite internet system connecting over 6 million users and counting worldwide. 

Recent reports have also indicated that Starlink has struck a deal with EchoStar to acquire 50 MHz of exclusive S-band spectrum in the United States and global Mobile Satellite Service (MSS) licenses. This should pave the way for Starlink to provide 5G coverage worldwide, even in remote areas. 

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