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SpaceX’s next Falcon Heavy launch may feature record-breaking center core landing

Falcon Heavy clears the top of the tower in a spectacular fashion during its debut launch. (Tom Cross/Pauline Acalin)

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Thanks to a temporary reopening of the US federal government, SpaceX was finally able to continue the process of filing FCC and FAA paperwork needed to acquire permits for upcoming launches, including Falcon Heavy.

One such filing related to the first operational Falcon Heavy launch has revealed a fairly impressive statistic: comprised of three first stage boosters, SpaceX indicated that Falcon Heavy’s center core will attempt to land on drone ship Of Course I Still Love You (OCISLY) nearly 1000 km (600 mi) away from its launch site, easily smashing the record for the greatest distance traveled by a Falcon booster in flight.

The same FCC filings also revealed a No Earlier Than (NET) launch date: March 7, 2019. Originally targeted for mid to late February, the complexity and logistical challenges of building, shipping, testing, and delivering two side boosters, a center core, one upper stage, and a payload fairing from SpaceX’s California factory to its Texas test facilities and Florida launch pad unsurprisingly took a small toll on the launch’s aspirational schedule. Nevertheless, if the launch data actually holds to March 7th, SpaceX will not have missed the mark by much considering that this Falcon Heavy – based on new and more powerful Block 5 boosters – is likely a significant departure from the Block 2/Block 3 hardware that has flight heritage from the triple-booster rocket’s Feb. 2018 launch debut.

The second (and third) flight of Falcon Heavy is even closer to reality as a new side booster heads to Florida after finishing static fire tests in Texas. (Reddit /u/e32revelry)

Just shy of a year after Falcon Heavy’s launch debut, it appears that the rocket’s second and third launches were pushed back by a fundamental lack of production capacity. In other words, SpaceX’s Hawthorne rocket factory simply had to focus on more critical priorities in the 6-9 months that followed the demo mission. At nearly the same time as Falcon Heavy was lifting off for the first time, SpaceX’s world-class production crew was in the midst of manufacturing the first upgraded Falcon 9 Block 5 booster (B1046) and wrapped up final checkouts just 10 days after Heavy’s Feb. 6 launch debut, sending the pathfinder rocket to McGregor, Texas for the first static fire of a Block 5 booster.

In the meantime, SpaceX’s decision to intentionally expend otherwise recoverable reused Falcon boosters after their second launches meant that the company’s fleet of flightworthy rockets was rapidly approaching zero, a move CEO Elon Musk specifically indicated was meant to make room for Block 5, the future (and final form) of the Falcon family. SpaceX’s busy 2018 launch manifest and multiple critical missions for the US government were thus balanced on the success, reliability, and rapid production of a serious number of Merlin engines, boosters, and upper stages. This included B1051 – the first explicitly crew-rated Falcon 9 – and B1054, the first SpaceX rocket rated to launch high-value US military (specifically Air Force) satellites. However, SpaceX also needed to produce a cadre of Falcon 9 boosters capable of easy reuse to support the dozen or so other commercial launches on the manifest.

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That gamble ultimately paid off, with Block 5 performing admirably and supporting a reasonable – if not record-breaking – rate of reuse. SpaceX successfully launched B1054 for the USAF, completed B1051 (now at Pad 39A awaiting NASA’s go-ahead), and built enough reusable Block 5 boosters to support nine additional commercial missions in 2018. In hindsight, barring an assumption of a truly miraculous and unprecedented Falcon booster production rate, Falcon Heavy’s next launches were almost guaranteed to occur no fewer than 6-12 months after the rocket’s launch debut – SpaceX’s entire launch business depended on building 5+ unrelated Falcon 9 boosters, while Falcon Heavy customers Arabsat and the USAF were unlikely to be swayed to launch on flight-proven hardware so early into Block 5’s career.

https://twitter.com/_TomCross_/status/1048483536917823488

All cylinders firing

Once Falcon 9 B1054 departed SpaceX’s Hawthorne factory (see above) in early October, it appears that the company’s production team pivoted directly to integrating and shipping the next three (or more) Falcon Heavy boosters back to back for the rocket’s second and third launches. The first new side booster departed the factory in mid-November, followed by a second side booster in early December and a (presumed but highly likely) center core at the turn of 2019. Both side boosters have been static-fired in Texas and are now at SpaceX’s Florida facilities, while the center core either just completed its Texas static fire testing or is already on its way East.

 

Once the center core and upper stage make their way to SpaceX’s Kennedy Space Center Pad 39A, the company’s technicians and engineers will be able to integrate the second Falcon Heavy to have ever existed in preparation for a critical static fire test. That could occur as early as February, although the launch debut of Crew Dragon (DM-1) – now NET March from Pad 39A after a relentless string of slips – will likely take precedence over Falcon Heavy and could thus directly interfere with its launch, as the launch pad and transporter/erector (T/E) has to undergo at least a few days of modifications to switch between Falcon 9 and Heavy.

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Regardless, the next two Falcon Heavy launches will be well worth the wait. SpaceX’s FCC filings indicate that the center core may travel nearly 1000 km (600 mi) East of Pad 39A to land on drone ship OCISLY after launch, smashing the previous record attempt – during the June 2016 launch of Eutelsat 117WB – of ~700 km (430 mi). That Falcon 9 booster – albeit a less-powerful Block 2 variant – was unsuccessful in its landing attempt, running out of oxidizer seconds before landing. Falcon Heavy’s debut center core also happened to suffer a wholly different but no less fatal anomaly during landing, causing it to miss the drone ship and slam into the Atlantic Ocean at almost half the speed of sound (300 mph/480 km/h).

Known for their rocket performance estimates, NASASpaceflight forum user “Orbiter” first pointed out the impressive distance – gathered by mapping coordinates included in SpaceX’s Jan. 28th FCC filing – and estimated that the Falcon Heavy center booster flying a trajectory as implied could be traveling as fast as ~3.5 km/s (2.2 mi/s) at main engine cut-off (MECO), the point at which the booster separates from the upper stage and fairing. This would be a nearly unprecedented velocity for any Falcon booster, let alone a booster with plans to land after launch. Falcon 9 MECO typically occurs at velocities between 1.5 and 2.5 km/s for recoverable missions, while even the recent expendable GPS III launch saw F9 S1’s engines cut off around 2.7 km/s.

Whether that MECO velocity estimate is correct, Falcon Heavy’s NET March launch of the ~6000 kg (13,300 lb) Arabsat 6A satellite is likely to be an exceptionally hot reentry and recovery for the center core, while the rocket’s duo of side boosters will attempt a repeat of the debut mission’s spectacular double-landing at LZ-1.


Check out Teslarati’s newsletters for prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket launch and recovery processes!

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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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SpaceX readies Starship Flight 14 for a historic journey into uncharted territory

SpaceX finished Starship’s Flight 14 rehearsal, clearing the way for its first orbital flight Monday.

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Sunrise at Starbase. Starship is stacked for opportunistic full-stack testing ahead of Flight 14 via SpaceX
Sunrise at Starbase. Starship is stacked for opportunistic full-stack testing ahead of Flight 14 via SpaceX

SpaceX has cleared one of the last hurdles before Starship’s first trip to orbit. The company posted on X Thursday afternoon that its launch rehearsal for Flight 14 was complete, keeping the mission on track for Monday, September 28. The launch window opens at 7:15 a.m. CT at Starbase, Texas, and runs for 75 minutes.

A wet dress rehearsal is essentially launch day without the launch. Crews fill Booster 21 and Ship 41 with thousands of tons of extremely cold propellant, run the countdown nearly to ignition, then drain everything back out. It lets engineers catch leaks or equipment problems before anything leaves the pad. SpaceX still needs a launch license from the FAA before the stack, which stands 407 feet tall, can fly.

Flight 14 matters because of where it is going. All 13 previous Starship flights followed a suborbital path, which works like throwing a ball extremely high and far: the vehicle reaches space, but it is always on a course that brings it back down within about an hour. This time, Ship 41 will perform a short engine firing called an orbital insertion burn roughly 25 minutes after liftoff, giving it enough speed to keep falling around Earth instead of back into it. SpaceX plans about six laps at an altitude near 275 kilometers (171 miles) over nearly 10 hours, as Teslarati detailed when the mission was first announced.


Getting into orbit also means Starship has to prove it can get back out. The ship must relight a single Raptor engine in space to slow down for reentry. SpaceX says it will only attempt the orbital insertion burn after flight controllers confirm the hardware needed for that return burn has enough backup, and its flight plan includes health checks that could shorten the mission to two or five orbits.

Flight 14 is also the first to put working satellites into service. Flight 13 carried 20 Starlink V3 satellites in July, but they came back down with the ship because that mission never reached orbit. This time, 26 V3 satellites are meant to stay up and join the constellation within a few weeks. Together they add about 26 terabits per second of network capacity, which SpaceX says is roughly 10 times what a single Falcon 9 launch of older V2 Mini satellites adds. Three of them carry cameras that will photograph Starship’s heat shield in orbit to check for tile damage before reentry.

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The hardware has changed too. Ship 41 flies with extra fasteners on tiles in the most vulnerable areas, fixes for gaps where superheated plasma slipped behind tiles, and curved tiles designed to reduce heating between them. Two tiles recovered from Ship 40 will fly again, the first reuse of any part of a Starship heat shield. Booster 21 carries better engine filtering and new relight software after ice clogged three center engines on the previous booster, leaving only eight of 13 engines to restart for its landing burn.

Ship 41 is targeting a splashdown in the Pacific Ocean west of Chile, a new recovery zone after several Indian Ocean landings, while Booster 21 aims for the Gulf. Neither will be caught by the tower on this flight. Elon Musk said in August that a ship catch was likely “in a few months.”

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Google just picked SpaceX for its first step into orbital AI

Google will launch its first Project Suncatcher AI satellite on SpaceX’s Transporter-18 rideshare next week.

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Google is about to put its own AI chips into orbit for the first time, and it is paying SpaceX to get them there.

The company said Thursday that the first in-orbit test of Project Suncatcher, its research effort to find out whether space can host large-scale AI computing, will fly next week on SpaceX’s Transporter-18 rideshare mission.

The satellite, called MVP, is about the size of a refrigerator and carries four of Google’s Tensor Processing Units, the same chips Google runs in its ground data centers. Google originally planned to launch two custom satellites in 2027, but chose to move faster by integrating its chips into a satellite.

MVP’s solar panels supply about one kilowatt of power, and Google will run Gemini models on the TPUs only in bursts of roughly 15 minutes before the chips shut down so the radiators can shed heat. In a blog post, Google said its Trillium TPUs survived vibration testing that mimicked sustained launch loads of up to 10g, with individual components seeing 50 to 100g, and handled a radiation dose greater than a five year mission would deliver.

SpaceX and Google mull massive partnership on Musk’s orbital data dream: report

Next week’s flight, slated for October 1, follows a relationship that became public in May, when Teslarati reported that Google was in talks with SpaceX for a launch deal tied to orbital data centers. Google also holds a stake of roughly 6% in SpaceX.

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The two companies are chasing the same idea from very different starting points. SpaceX’s own orbital compute program is built around the AI1 satellite, a roughly 70 meter structure derived from Starlink V3 hardware that is designed for 150 kW of peak compute, about 150 times the power MVP will draw. Elon Musk has brushed off concerns about crowding orbit with those satellites, and SpaceX is building its Gigasat factory in Bastrop, Texas, to produce them, targeting an annualized rate of about 1 GW of space compute by the end of 2027.

Musk also posted on X on Thursday that “the amount of compute in space will obviously round up to 100% of all compute.”

Google has been more cautious in public. Its research estimates that launch prices need to fall below about $200 per kilogram before an orbital data center can compete with a ground facility on energy cost, a threshold the company believes could be reached around the mid 2030s. The Suncatcher team has said it expects the effort to remain a project rather than a product for years, which leaves the first real test of its hardware riding on a rocket from the company with the most aggressive timeline in the field.

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Tesla Cybercab gets initial tie-in to localized, in-house cathode plant

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Credit: Tesla

Tesla has taken another concrete step toward owning its battery supply chain, and it’s doing so with what is perhaps the most important vehicle in its short-but-storied history.

On September 23, Tesla announced that it has officially built the first Cybercab with cathode material produced in-house at the company’s first cathode plant in the U.S., and the first in the U.S. overall.

Active cathode material is the most expensive piece of a lithium-ion battery cell, and it often accounts for more than a third of cell cost. For years, the industry sourced a majority of it from Asia, but Tesla’s decision to make it in the United States bodes well for the Cybercab project. This is the latest chapter in Tesla’s vertical integration strategy, which began in public at Battery Day in 2020.

At the Battery Day Event, Elon Musk said the company would build a North American cathode plant and overhaul the process to cut costs and waste, while also making some of the most powerful and long-lasting cells in the industry.

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The Austin facility took years to appear. Tesla filed permits for “Project Cathode” in 2022 on land near Giga Texas. By mid-2022, the building frame was up and Tesla later invested hundreds of millions of dollars as part of a larger expansion of the Giga Texas plant. The company stated it was operating the first large-scale cathode production facility in North America to supplement 4680 cell production.

One month later, that material reached a finished Cybercab.

The timing of this breakthrough is monumental for the Cybercab program. As Tesla officially launched the first Cybercab rides to the public earlier this month, production of the ride-hailing-geared vehicle is moving forward on the planned S-curve that CEO Elon Musk told everyone to expect.

Nevertheless, packs of Cybercab units have been spotted throughout the United States, in an effort to potentially activate the fleet as soon as the company gains regulatory approval in various geographic areas.

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On top of that, Tesla owning the cathode step and pairing it with its own in-house lithium from the Gulf Coast refinery shortens the supply chain that once stretched thousands of miles and subjects every pack to fewer external price shocks and geopolitical risks.

Tesla is not yet independent of all of its foreign suppliers, as some precursor metals come from mines and chemical plants. But the first in-house cathode Cybercab shows the company is closing the most expensive and most concentrated gap in its battery production efforts. For a vehicle like Cybercab to operate at a high utilization within the Robotaxi network, that control over cost is so crucial.

It is arguably as important as the software that drives it.

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