Space
SpaceX is already preparing for operational astronaut missions
While the world’s attention is focused on the return of orbital human spaceflight from US soil after a nearly decade long absence with the upcoming May 27th Crew Dragon Demo-2 mission, SpaceX is simultaneously preparing for the first Crew Dragon operational mission certified by NASA, dubbed Crew-1, slated to occur later this year.
On Friday, April 24th, SpaceX treated its Twitter followers to some rare imagery of static fire testing completed at the company’s development facility in McGregor, Texas. The company spotlighted a fresh-from-the-factory Falcon 9 booster and Falcon 9 second stage Merlin Vaccum (MVac) engine intended for the Crew-1 mission. Crew-1, the follow-up mission to May’s Demo-2 mission and SpaceX’s first operational human spaceflight mission for NASA, will propel a crew of three NASA astronauts and one JAXA astronaut in a Crew Dragon capsule to the International Space Station.
SpaceX also provided its followers with a view of the pristine second stage MVac engine of the Crew-1 mission before it was sent to Texas for testing. The one-hundredth production MVac engine is seen inside of SpaceX’s manufacturing facility located in Hawthorne, CA before being prepared for shipment. The second stage MVac engine is the only piece of Falcon 9 hardware that SpaceX does not actively recover and reuse, unlike the first-stage booster and protective payload fairing nosecone.
Part of the process
A static fire test is a typical occurrence before shipping the booster and second stage to Florida for payload integration and launch. The static fire process involves holding down the booster and igniting the engines to run for a full-duration firing. A similar test is also performed on with the second stage MVac engine. These test-fires are performed at the Mcgregor facility to proof the vehicle and check for any inconsistencies or off-nominal test readings that may occur before shipping to the vehicle to the launch site. Following the test-fire, the entire vehicle is inspected, cleaned, and prepared for shipment.
A test-fire in Mcgregor is not the last time the engines will be put through the paces before launch. Typically a week or so before the scheduled launch date, the Falcon 9 booster is transported to the launch pad. There, the booster is fully fueled with propellant while securely held to the launch mount. All nine Merlin-1D engines are once again ignited briefly (anywhere between 6 – 12 seconds) to test the propellant load process and collect engine-firing measurements such as temperature and pressure.
Certification before operation
Although the Crew-1 mission is tentatively on the books for later this year, SpaceX and the Crew Dragon capsule have yet to achieve NASA certification to begin operational missions to and from the International Space Station. The second orbital demonstration flight of the Crew Dragon capsule (Demo-2) will serve as the final end-to-end test of SpaceX’s crew transportation system.
However, SpaceX still faces a few obstacles before achieving a full go-ahead by NASA for the launch of Demo-2. As reported by SpaceNews.com NASA’s Aerospace Safety Advisory Panel (ASAP) met via teleconference on Thursday, April 23rd for a routine quarterly briefing. In that meeting, it was briefly discussed that there are still a few “technical items” that remain to be cleared by NASA before the launch of the Demo-2 mission.
Although not specified in the briefing – and likely to be followed up on during “part 2” of the ASAP meeting to be held in early May – those items likely refer to wrapping up the joint investigation of a recent in-flight engine failure of a Falcon 9 Merlin-1D engine and one more qualifying drop-test of the Crew Dragon Mark 3 parachutes. SpaceX, however, shows no plans letting formalities stop the preparation to support future astronaut missions.
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SpaceX is ready to bring home Butch Wilmore and Suni Williams, the two astronauts that have been stranded on the International Space Station (ISS) for nine months.
Last week, SpaceX launched its Crew-10 mission, which would dock onto the ISS late Saturday night and be the two astronauts’ ride home. Now, the end is in sight, and it appears both NASA and SpaceX are planning to have the two home this week, perhaps earlier than expected.
SpaceX readies to rescue astronauts from International Space Station
The agency and the company have announced that Dragon will autonomously undock from the ISS on Tuesday at 1:05 a.m. ET and should re-enter Earth’s atmosphere and splashdown off the Florida coast about 17 hours later.
SpaceX said:
“SpaceX and NASA are targeting Tuesday, March 18 at 1:05 a.m. ET for Dragon to autonomously undock from the International Space Station. After performing a series of departure burns to move away from the space station, Dragon will conduct multiple orbit-lowering maneuvers, jettison the trunk, and re-enter Earth’s atmosphere for splashdown off the coast of Florida approximately 17 hours later the same day.”
Crew-9 astronaut Nick Hague will be alongside Williams and Wilmore on the flight home, along with Roscosmos cosmonaut Aleksandr Gorbunov. Hague and Gorbunov have been in space since Saturday, September 28.
SpaceX was tasked with bringing Wilmore and Williams home after the Boeing Starliner that sent them there was determined not to be suitable for their return.
A report from the New York Post in late August said that Boeing employees routinely made fun of SpaceX workers, only for the company to bail them out:
SpaceX bails out Boeing and employees are reportedly ‘humiliated’
Crew-10 will bring the astronauts home, ending an extensive and unscheduled stay in space.
SpaceX is readying to launch the Crew-10 mission this evening, which will bring home U.S. astronauts Butch Wilmore and Suni Williams, who have been stuck on the International Space Station for nine months.
SpaceX is working alongside NASA to bring the two astronauts home, and all systems and weather conditions are looking ideal to launch the mission this evening from the Kennedy Space Center in Florida.
All systems are looking good and weather is exceptional for tonight’s Falcon 9 launch of @NASA‘s Crew-10 to the @Space_Station → https://t.co/VPdhVwQFNJ pic.twitter.com/wZ9LvZAnYn
— SpaceX (@SpaceX) March 14, 2025
Boeing was originally tasked with the rescue mission.
The company sent a Starliner aircraft to the ISS in late September in an effort to bring Williams and Wilmore home. However, malfunctioning thrusters and other issues on the Starliner aircraft prevented NASA from giving the green light to the astronauts to board and come home.
SpaceX was then tasked with bringing the two home, and it appears they will be on their way shortly.
The launch was intended to occur on Wednesday, but a last-minute problem with the rocket’s ground systems forced SpaceX and NASA to delay until at least Friday. Things are looking more ideal for a launch this evening.
The launch is targeted for 7:03 p.m. ET, but another backup opportunity is available tomorrow, March 15, at 6:41 p.m.
SpaceX writes about the Dragon spacecraft that will be used for the mission:
“The Dragon spacecraft supporting this mission previously flew NASA’s Crew-3, Crew-5, and Crew-7 missions to and from the space station. This will be the second flight for the first stage booster supporting this mission, which previously launched the SES 03b mPOWER-e mission. Following stage separation, Falcon 9’s first stage will land on Landing Zone 1 (LZ-1) at Cape Canaveral Space Force Station.”
The mission will not only aim to bring the two astronauts who have been stranded for nine months home, but it will also conduct new research to prepare for human exploration beyond low-Earth orbit.
If Crew-10 launches at the planned time this evening, it will dock to the ISS at 11:30 p.m. ET on Saturday night.
SpaceX is set to launch its eighth test flight of the Starship rocket this Friday. Ahead of the most recent test in what could be the most revolutionary spaceflight program since NASA’s Apollo, SpaceX is clearing the air about what went wrong during its previous test flight, which resulted in the loss of the second stage during its ascension.
On January 16, SpaceX successfully launched Starship while also completing its second successful catch of the lower-stage booster.
However, the flight did not go as smoothly as initially anticipated, as the company lost Starship’s upper stage roughly eight minutes and twenty seconds into flight.
Now, the company is clarifying what happened that led to the demise of the upper stage, which SpaceX has identified with the recognition of “flashes” that occurred after vehicle separation.
SpaceX completes second catch of lower stage, but loses Starship
SpaceX says that a flash was observed roughly two minutes into its burn after vehicle separation. The flash, along with sensors that was a pressure rise in the attic, indicated a leak:
“Approximately two minutes into its burn, a flash was observed in the aft section of the vehicle near one of the Raptor vacuum engines. This aft section, commonly referred to as the attic, is an unpressurized area between the bottom of the liquid oxygen tank and the aft heatshield. Sensors in the attic detected a pressure rise indicative of a leak after the flash was seen.”
This was not the only flash that was observed. Two minutes after the first, another flash was seen, but this one was followed by sustained fires in the attic. These fires caused Starship’s engines to perform a controlled shutdown:
“These eventually caused all but one of Starship’s engines to execute controlled shut down sequences and ultimately led to a loss of communication with the ship. Telemetry from the vehicle was last received just over eight minutes and 20 seconds into flight.”
SpaceX clarified that Starship was destroyed and communication with the ship was lost before it was able to initiate any destruct rules for its Autonomous Flight Safety System. The company said this was “fully healthy when communication was lost.”
It went on to say that the “most probable root cause” of the loss was likely due to an environment not seen during testing:
“The most probable root cause for the loss of ship was identified as a harmonic response several times stronger in flight than had been seen during testing, which led to increased stress on hardware in the propulsion system. The subsequent propellant leaks exceeded the venting capability of the ship’s attic area and resulted in sustained fires.”
Nevertheless, Starship will launch for the eighth time soon, with CEO Elon Musk noting that the most likely date will be Friday. This could be the second of potentially 25 Starship launches planned for 2025.
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