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SpaceX and NASA accidentally set the stage for a new race to the Moon
Almost entirely driven by chance, SpaceX and NASA may soon find themselves in an unintentional race to return humans to the Moon for the first time in half a century.
Both entities – SpaceX with its next-generation BFR and NASA with its Shuttle-derived SLS – are tentatively targeting 2023 for their similar circumlunar voyages, in which NASA astronauts and private individuals could theoretically travel around the Moon within just months of each other, showcasing two utterly dissimilar approaches to space exploration.
Over the course of no fewer than seven years of development, NASA’s SLS rocket and Orion spacecraft have run into an unrelenting barrage of issues, effectively delaying the system’s launch debut at a rate equivalent to or even faster than the passage of time itself. In other words, every month recently spent working on the vehicle seems to have reliably corresponded with at least an additional month of delays for the launch system.
Why these incessant delays continue to occur is an entire story in itself and demands the acknowledgment of some uncomfortable and inconvenient realities about the state of NASA’s human spaceflight program in the 21st century, but that is a story is for another time.
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- SLS. (NASA)
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- NASA’s Orion spacecraft, European Service Module, and ICPS upper stage. (NASA)
A different kind of paper rocket
Returning to SLS, a brief overview is in order to properly contextualize what exactly the rocket and spacecraft are and what exactly their development has cost up to now. SLS is comprised of four major hardware segments.
- The Core Stage: A massive liquid hydrogen/liquid oxygen rocket booster, this section is essentially a lengthened version of the retired Space Shuttle’s familiar orange propellant tank, while the stage’s four engines are quite literally taken from stores of mothballed Space Shuttle hardware and will be ingloriously expended after each launch (SLS is 100% expendable).
- Solid Rocket Boosters (SRBs): Minimally modified copies of the SRBs used during the Space Shuttle program, SLS’ SRBs have slightly more solid propellant and have had all hints of reusability removed, whereas Space Shuttle boosters deployed parachutes and were reused after landing in the Atlantic Ocean.
- The Upper Stage (Interim Cryogenic Propulsion System, ICPS): ICPS is a slightly modified version of ULA’s off-the-shelf Delta IV upper stage.
- The Orion spacecraft and European Service Module: Borrowing heavily from the Apollo Command and Service Modules that took humanity to the Moon in the 1960s and 70s, Orion has been in funded development in one form or another for more than 12 years, with just one partial flight-test to call its own. Orion’s development has cost the U.S. approximately $16 billion since 2006, with another $4-6 billion expected between now and 2023, a sum that doesn’t account for the costs of production and operations once development is complete.
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- The Orion spacecraft and ESM. (NASA)
For the SLS core stage and SRBs, a generous bottom-rung estimate indicates that $14 billion has been spent on the rocket itself between 2011 and 2018, not including many billions more spent refurbishing and modifying the rocket’s aging Saturn and Shuttle-derived launch infrastructure at Kennedy Space Center. Of the many distressing patterns that appear in the above descriptions of SLS hardware, most notable is a near-obsessive dependence upon “heritage” hardware that has already been designed and tested – in some cases even manufactured.
Despite cobbling together or reusing as many mature components, facilities, and workforces as possible and relying on slightly-modified commercial hardware at every turn, SLS and Orion will somehow end up costing the United States more than $30 billion dollars before it has completed a single full launch; potentially rising beyond $40 billion by the time the system is ready to launch NASA astronauts.
Moonward bound
SLS’ first crewed mission, known as Exploratory Mission-2 (EM-2), brings us to the title – NASA’s mission planning has settled on sending a crew of four astronauts on what is known as a Free Lunar Return trajectory in the Orion spacecraft, essentially a single flyby of the Moon. Official NASA statements appear to be sending mixed messages on the schedule for EM-2’s launch, with September 2018 presentations indicating 2022 while a late-August blog post suggests that the crewed circumlunar mission is targeting launch in 2023.
As it happens, SpaceX announced its own plans for a (private) crewed circumlunar voyage less than two weeks ago. Funded in large part by Japanese billionaire Yasuka Maezawa, SpaceX’s hopes to send 10+ people to the Moon on its next-generation BFR launch vehicle, comprised of a fully-reusable booster and spaceship. Deemed Dear Moon by Maezawa, SpaceX is targeting an extremely ambitious launch deadline sometime in 2023, although CEO Elon Musk frankly noted that hitting that 2023 window would require all aspects of BFR booster and spaceship development to proceed flawlessly over the next several years.
Compared to the 10+ years and $30+ billion of development SLS and Orion will have taken before their first full launch, SpaceX is targeting the first orbital BFR test flights as early as 2020 or 2021, self-admittedly optimistic deadlines that will likely slip. Still, betting against SpaceX completing its first BFR launch sometime in the early to mid-2020s for something approximating Musk’s $2-10 billion development cost seems a risky move in the context of SpaceX’s undeniable track record of proving the old-guard wrong.
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- NASA’s EM-2 circumlunar voyage. (NASA)
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- SpaceX’s own circumlunar trajectory, nearly identical. (SpaceX)
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- SLS Block 1. (NASA)
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- BFR’s spaceship and booster (now Starship and Super Heavy) separate in a mid-2018 render of the vehicle. (SpaceX)
It must be noted that the apparent alignment of both SpaceX and NASA’s first crewed circumlunar missions with new rockets and spacecraft is a fluke of chance, and the fact that it may or may not take the shape of a second race to the Moon – pitting two dramatically different ideologies and organizational approaches against each other – is purely coincidental.
However, despite the undeniable fact that NASA and SpaceX are deeply and cooperatively involved through Crew and Cargo Dragon and despite Musk’s genuine affirmations of support and admiration for the space agency, it can be almost guaranteed that the world will look on in the 2020s with the same underlying emotions and motivations that were globally present during the Apollo Program. Rather than a battle of economic and nationalistic ideologies, the New Space Race of the 2020s will pit two (publicly) amicable private and public entities against each other at the same time as they work hand-in-hand to deliver crew and cargo to the International Space Station.
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- An overview of BFR’s booster and spaceship, now known as Super Heavy and Starship. (SpaceX)
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- SpaceX has already completed the first of many carbon-composite sections of its prototype spaceship. (SpaceX)
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- SLS’ movable launch pad is very slowly being prepared for a 2020/2021 debut. (Tom Cross)
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- SLS undoubtedly has several steps up on BFR in terms of volume of hardware in work, although target launch dates are quite similar for both rockets. (NASA)
Critically, this new “race” will be fairly illusory. Thanks to the fact that the new goal of human spaceflight appears to be the sustainable exploration of the solar system, there will inherently be no Apollo-style finish line for any one company or country or agency to cross. Rather than the Apollo Program’s shortsighted economic motivations and its consequentially abrupt demise, the end-result of this new age of competition will be the establishment of humanity as a (deep) spacefaring species, be it a temporary burst of effort or a permanent human condition.
Buckle up.
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Elon Musk
Tesla reveals Optimus Academy, where robots teach themselves
Tesla has begun building production quality Optimus robots in Fremont and revealed its training plan.
Tesla has started building Optimus on the high volume line it set up inside its Fremont factory, and the company says the robots coming off it are the first that meet the bar for a real product. “The bots coming off this line are the first production-quality bots that we have manufactured,” Tesla wrote in its third quarter shareholder letter, adding that it has “proven that the current manufacturing process for Optimus is suitable for a commercial product.”
The line sits in space that built the Model S and Model X until this spring. Tesla cleared the old vehicle line in 46 days, as Teslarati reported in July, to make room for robot production sized for one million units a year. On Wednesday’s earnings call, Elon Musk said most of the equipment for that capacity is already in Fremont, with output set to climb toward roughly 20,000 robots a week as the line ramps.
Musk described the ramp as a classic S curve. “The growth of Optimus is an S curve, but the initial curve is a shallow slope,” he said. The team is now refining the robot’s AI, electromechanical design, reliability and service life, and Musk expects that work to be finished by the end of next year, when Tesla plans to start delivering Optimus to outside companies for dangerous, repetitive and around the clock jobs.
The most interesting part of the call was how Tesla plans to teach the robots. Its cars send real driving data back to the AI team from millions of vehicles, but Optimus has no fleet like that yet. “A big difference with Optimus versus the cars is we don’t have this vast fleet of cars from which we can gather training data,” Musk said. Tesla’s answer is an Optimus Academy, where 10,000 to 20,000 robots will practice a wide range of tasks and feed what they learn into the next version of the model. Every unit off the Fremont line becomes a source of that training data.
Smarter hardware is on the way too. Tesla plans to put its AI5 chip into Optimus next year, and Musk said a new Optimus video should arrive within one or two months showing the robot completing tasks driven by AI rather than preprogrammed motions. He took aim at rival humanoid demos that only run scripted routines, saying those would not hold up in the real world.
The supply chain is lining up behind the program. In September, Tesla certified Tuopu, Joyson and Sanhua as mass production partners for Optimus components. A far larger Optimus factory is also rising at Giga Texas, where drone footage from Joe Tegtmeyer showed the steel frame nearing completion, and Musk has pegged that plant’s long term target at 10 million robots a year.
Tesla executives also said Optimus production costs are trending toward the expected manufacturing cost of Cybercab, a sign the robot is being engineered for volume from the start. The hands remain the toughest piece of the design, a point Musk also made at the X Takeover event earlier this month, as Teslarati covered at the time, and that is where much of the current engineering effort is focused.
Elon Musk
The Starship moon landing number NASA and Elon Musk can’t agree on
Musk disputes NASA estimate of 22 Starship launches for Moon landing, predicting 6 to 8.
Elon Musk is disputing a new NASA safety panel estimate of how many Starship launches it will take to put astronauts on the Moon, saying the real number will be less than half the panel’s figure.
On Thursday, NASA’s Aerospace Safety Advisory Panel held its quarterly public meeting. Panel member Charlie Precourt, a former NASA astronaut, flagged the fueling process for SpaceX’s lunar lander as a major risk for Artemis IV, the mission planned to land a crew on the Moon in 2028. “We need to keep our eyes on numerous required fuelings for the lander,” Precourt said, according to Ars Technica. “I think the last estimate is around 22 flights.”
Ars Technica’s Eric Berger posted the comment on X, and Musk replied. “That’s way too high,” Musk wrote. “Actual number will be more like 6 to 8.”
The disagreement comes down to a basic problem with sending a ship as large as Starship to the Moon. Starship burns nearly all of its propellant just reaching Earth orbit, so it cannot continue on to the Moon without stopping for a refill. SpaceX’s answer is a gas station in space. First, a Starship that works as a storage tank, called a depot, is launched into orbit. Then a series of tanker Starships launch one at a time, dock with the depot and pump their leftover propellant into it. Once the depot is full, the lunar lander version of Starship launches, docks, fills up and heads for the Moon.
Every tanker trip is its own full rocket launch, which is why the count matters. More launches mean more time, more cost and more chances for something to go wrong before astronauts ever leave Earth. Berger estimated that even if SpaceX reaches twice weekly Starship launches by the end of 2027, filling a depot at the panel’s number would still take roughly three months.
How many tankers are needed depends mostly on how much propellant each one can carry to orbit and how much is lost along the way. Starship’s fuel and oxygen are stored at extremely cold temperatures, and some of it slowly boils off while waiting in orbit. More is lost in each transfer. NASA appears to be working from what Starship can lift today, while Musk’s range assumes a more capable rocket.
Musk has pushed back on higher counts before. In 2021, after a government document suggested 16 launches, he called that “extremely unlikely” and said eight tankers would be the most required.
Much of the answer depends on hardware SpaceX has not finished flying. As Teslarati noted earlier this year, the company plans to carry out the refueling process with its upgraded V3 Starship, and Precourt described Artemis IV as carrying “a large number of firsts.” He also praised NASA Administrator Jared Isaacman’s team for working to clear obstacles for both SpaceX and Blue Origin, whose Blue Moon lander does not rely on orbital refueling for its first mission.
Elon Musk
Tesla’s secretive “Project Crystal Sun” gets a big green light in Texas
Fort Bend County approved four incentive agreements Thursday for Tesla’s proposed $10.1 billion solar factory.
Fort Bend County commissioners on Thursday approved a package of tax incentives for Tesla’s proposed $10.1 billion solar cell factory near Needville, Texas, giving the company one of the last local approvals it needs before it decides where to build. All four Tesla agreements passed 4 to 0.
The votes covered a property tax abatement inside Reinvestment Zone No. 34, a Chapter 381 economic development agreement, a foreign trade zone non-objection paired with payments in lieu of certain taxes, and a separate payment in lieu of taxes “true up” agreement, according to agenda notes from the Fort Bend Commissioners Court meeting.
The project, known internally as “Project Crystal Sun,” would make solar cells and finished modules on roughly 3,000 acres near FM 762 and FM 1994, south of the Brazos River. As Teslarati reported when the filing first surfaced in August, Tesla’s application under the state’s JETI Act splits the investment into $1.5 billion in real property and $8.6 billion in equipment, with 9,712 permanent jobs projected by 2033 and commercial operations targeted for the first quarter of 2029. The plant would handle the full chain from ingot and wafer production through cell testing.
Inside Tesla’s secretive $10 Billion “Project Crystal Sun” filing
Thursday’s approval does not lock in the site. Tesla has told the Texas Comptroller it is still weighing other locations, and site selection adviser David Dennison told Lamar Consolidated ISD trustees in September that the race had narrowed to Fort Bend and one out of state rival with a “very compelling package,” according to the Houston Chronicle. Tesla hopes to decide before the end of 2026, and the incentives still need sign off from the Comptroller and the Governor’s office.
Local officials have now done nearly everything within their control. Commissioners created the reinvestment zone in an August 24 special meeting, with Interim County Judge Daniel Wong formally withdrawing himself over his engineering firm’s past work with Tesla. Lamar CISD trustees voted 7 to 0 on September 15 to advance a JETI agreement that would tax Tesla’s qualifying property at 50 percent of its value for maintenance and operations from 2029 through 2038.
The plant lines up with a target Elon Musk set on Tesla’s Q4 2025 earnings call in January, when he said the company would “work toward getting 100 GW a year of solar cell production, integrating across the entire supply chain from raw materials all the way to finished solar panels.” In March, Tesla was reported to be negotiating a $2.9 billion purchase of Chinese solar manufacturing equipment bound for Texas. The Houston area already hosts Tesla’s Megafactory in Brookshire, where Megapack 3 production has started. Tesla said on its Q3 call that Megapack supply for 2027 is nearly sold out, and Musk wrote on X Thursday that the company is “increasing production of Megapacks as much as possible,” as demand from data centers climbs.
Tesla reveals Optimus Academy, where robots teach themselves
The Starship moon landing number NASA and Elon Musk can’t agree on
