SpaceX
SpaceX’s Mr. Steven highlights ambiguity of Falcon fairing catches with port return
SpaceX’s fairing recovery vessel Mr. Steven highlighted the maddening and exhilarating uncertainty of unpublicized fairing recovery attempts with a return to Port of San Pedro on October 18th, the morning after spending a day at sea for the second Falcon fairing drop-and-catch test.
Teslarati photographer Pauline Acalin was on site to watch Mr. Steven’s 1AM Pacific port return and was able to capture the arrival, showing a familiar test fairing resting on the vessel’s deck, perfectly intact, with the recovery net fully retracted.
Schrödinger’s Fairing
Beginning with a dry run on October 8th, SpaceX technicians and engineers have spent the last 10 days testing Mr. Steven more intensely than ever previously observed, centering around a campaign of apparent Falcon fairing drop tests. Although it’s possible that these tests are more captive-carry trials than true drop tests, it seems more likely – judging by the fact that NOTAMs, notices to airmen, were only filed for 2 of the 3 attempts – that the helicopter is actually releasing a fairing half around 11,000 feet (3300 m) and letting it glide towards Mr. Steven.
Previously, SpaceX executive Hans Koenigsmann and CEO Elon Musk have mentioned a probable drop test campaign if operational (post-launch) fairing recovery attempts were unsuccessful. Mr. Steven has yet to successfully snag a fairing out of the air over the course of four post-launch catch attempts, evidence that – just like landing Falcon 9 boosters intact – recovering orbital-class rocket hardware in a state that allows for future reuse is extraordinarily difficult, regardless of the subsystem. However, SpaceX has managed to successfully recover fairing halves intact and in a condition good enough to make Koenigsmann, Vice President of Reliability, visibly excited during an IAC 2018 presentation.
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- Hans Koenigsmann was extremely excited about the condition of this particular fairing half, and included this photo in his IAC 2018 keynote. (SpaceX)
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- One half of SpaceX’s Iridium-6/GRACE-FO just moments before touchdown on the Pacific Ocean. (SpaceX)
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- Close. (SpaceX)
The problem with those intact halves is that they have been recovered only after soft landings in the ocean – once immersed in saltwater, the sheer expense of cleaning a fairing to the point that it would be able to host another sensitive satellite payload is apparently too high to be worthwhile, at least from a perspective of economical reusability. The (quite literally) miniscule line that thus appears to be separating failed fairing recovery attempts from successes also means that it’s extraordinarily difficult to know whether the fairing half that returned on Mr. Steven yesterday morning is indicative of a breakthrough success or another successful failure.
Clearly, the fairing is perfectly intact from a purely structural perspective, meaning that its recovery hardware – cold gas thrusters and a parafoil – worked nominally. What is impossible to tell is whether its autonomous guidance systems were able to successfully direct it to Mr. Steven’s net, or whether Mr. Steven himself was able to maneuver beneath the falling fairing in time to catch it. And yet, a fairing half still sits visibly intact on Mr. Steven’s deck, story and fate unknown. With any luck, SpaceX will offer an official confirmation of some sort once success is in hand. For now, we wait.
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Elon Musk
SpaceX issues statement on Starship V3 Booster 18 anomaly
The incident unfolded during gas-system pressure testing at the company’s Massey facility in Starbase, Texas.
SpaceX has issued an initial statement about Starship Booster 18’s anomaly early Friday. The incident unfolded during gas-system pressure testing at the company’s Massey facility in Starbase, Texas.
SpaceX’s initial comment
As per SpaceX in a post on its official account on social media platform X, Booster 18 was undergoing gas system pressure tests when the anomaly happened. Despite the nature of the incident, the company emphasized that no propellant was loaded, no engines were installed, and personnel were kept at a safe distance from the booster, resulting in zero injuries.
“Booster 18 suffered an anomaly during gas system pressure testing that we were conducting in advance of structural proof testing. No propellant was on the vehicle, and engines were not yet installed. The teams need time to investigate before we are confident of the cause. No one was injured as we maintain a safe distance for personnel during this type of testing. The site remains clear and we are working plans to safely reenter the site,” SpaceX wrote in its post on X.
Incident and aftermath
Livestream footage from LabPadre showed Booster 18’s lower half crumpling around the liquid oxygen tank area at approximately 4:04 a.m. CT. Subsequent images posted by on-site observers revealed extensive deformation across the booster’s lower structure. Needless to say, spaceflight observers have noted that Booster 18 would likely be a complete loss due to its anomaly.
Booster 18 had rolled out only a day earlier and was one of the first vehicles in the Starship V3 program. The V3 series incorporates structural reinforcements and reliability upgrades intended to prepare Starship for rapid-reuse testing and eventual tower-catch operations. Elon Musk has been optimistic about Starship V3, previously noting on X that the spacecraft might be able to complete initial missions to Mars.
Elon Musk
SpaceX Starship Version 3 booster crumples in early testing
Photos of the incident’s aftermath suggest that Booster 18 will likely be retired.
SpaceX’s new Starship first-stage booster, Booster 18, suffered major damage early Friday during its first round of testing in Starbase, Texas, just one day after rolling out of the factory.
Based on videos of the incident, the lower section of the rocket booster appeared to crumple during a pressurization test. Photos of the incident’s aftermath suggest that Booster 18 will likely be retired.
Booster test failure
SpaceX began structural and propellant-system verification tests on Booster 18 Thursday night at the Massey’s Test Site, only a few miles from Starbase’s production facilities, as noted in an Ars Technica report. At 4:04 a.m. CT on Friday, a livestream from LabPadre Space captured the booster’s lower half experiencing a sudden destructive event around its liquid oxygen tank section. Post-incident images, shared on X by @StarshipGazer, showed notable deformation in the booster’s lower structure.
Neither SpaceX nor Elon Musk had commented as of Friday morning, but the vehicle’s condition suggests it is likely a complete loss. This is quite unfortunate, as Booster 18 is already part of the Starship V3 program, which includes design fixes and upgrades intended to improve reliability. While SpaceX maintains a rather rapid Starship production line in Starbase, Booster 18 was generally expected to validate the improvements implemented in the V3 program.
Tight deadlines
SpaceX needs Starship boosters and upper stages to begin demonstrating rapid reuse, tower catches, and early operational Starlink missions over the next two years. More critically, NASA’s Artemis program depends on an on-orbit refueling test in the second half of 2026, a requirement for the vehicle’s expected crewed lunar landing around 2028.
While SpaceX is known for diagnosing failures quickly and returning to testing at unmatched speed, losing the newest-generation booster at the very start of its campaign highlights the immense challenge involved in scaling Starship into a reliable, high-cadence launch system. SpaceX, however, is known for getting things done quickly, so it would not be a surprise if the company manages to figure out what happened to Booster 18 in the near future.
Elon Musk
SpaceX’s next project will produce Starships at a level that sounds impossible
1,000 rockets per year is an insane number, especially considering Starship’s sheer size.
Elon Musk has revealed bold plans for SpaceX’s newest Starbase facility in Texas, predicting it will become a birthplace for “so many spaceships.” The upcoming “Gigabay,” a massive $250 million production hub in Starbase, Texas, is designed to manufacture up to 1,000 Starship rockets per year.
That’s an insane number of rockets for a single facility, especially considering Starship’s sheer size.
One of the world’s largest industrial structures
SpaceX’s Gigabay is expected to stand roughly 380 feet tall and enclose 46.5 million cubic feet of interior space, making it one of the largest industrial structures to date. The facility will feature 24 dedicated work cells for assembling and refurbishing Starship and Super Heavy vehicles, complete with heavy-duty cranes capable of lifting up to 400 U.S. tons, as noted in a Times of India report.
Construction crews have already placed four tower cranes on-site, with completion targeted for December 2026. Once operational, the Gigabay is expected to boost SpaceX’s launch cadence dramatically, as it would be able to build up to 1,000 reusable Starships per year, as noted in a report from the Dallas Express. Musk stated that the Gigabay will be “one of the biggest structures in the world” and hinted that it represents a major leap in Starbase’s evolution from test site to full-scale production hub.
A key step toward Mars and beyond
Starship is SpaceX’s heavy-lift rocket system, and it remains a key part of Elon Musk’s vision of a multiplanetary future. The vehicle can carry 100–150 tonnes to low Earth orbit and up to 250 tonnes in expendable mode. With several successful flights to date, including a perfect 11th test flight, the Starship program continues to refine its reusable launch system ahead of crewed lunar missions under NASA’s Artemis initiative.
Starship is unlike any other spacecraft that has been produced in the past. As per Elon Musk, Starship is a “planet-colonizer” class rocket, as the magnitude of such a task “makes other space transport task trivial.” Considering Starship’s capabilities, it could indeed become the spacecraft that makes a Moon or Mars base feasible.
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