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SpaceX reusability may soon be in good company as Rocket Lab catches rocket with a helicopter

A screenshot of Rocket Lab's recet "mid-air recovery" test shows a helicopter outfitted with a specialized grappling hook snagging an Electron booster test article.

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Rocket Lab, the world’s most prominent dedicated small satellite launcher, has made significant headway on plans to recover and reuse the booster stage of its Electron rocket, meaning that SpaceX’s reusable Falcon rockets could finally have company.

Recovering a booster is perhaps where all similarities end, however. While the SpaceX Falcon 9 gracefully guides itself back for a controlled landing on an ocean-going drone ship or land-based landing zone, Rocket Lab’s Electron booster will be snagged straight out of the air by a helicopter with a grappling hook.

A screenshot of Rocket Lab’s recet “mid-air recovery” test shows a helicopter outfitted with a specialized grappling hook snagging an Electron booster test article.

Recently, Rocket Lab completed what the company called “a major step forward” in plans to achieve full booster recoverability with the successful completion of a “mid-air recovery” test. The test occurred over the open ocean near New Zealand and featured what was identified as an “Electron first stage test article.” One helicopter released the test article at a low altitude – around 2.5km (8,000ft) – and a nearby second helicopter, outfitted with a specially designed grappling hook, swooped in and snatched it out of the sky as it plummeted toward the ocean.

Rocket Lab’s recovery efforts did not simply begin with dropping a rocket-shaped test article from a helicopter. Long before ever attempting to catch a test article falling through the sky, the company had to ensure that the first stage of the Electron booster could even survive the return trip. Rocket Lab CEO and founder, Peter Beck, referred to it as punching through the wall which best summarizes the conditions that the first stage encounters upon re-entry through on the Earth’s dense atmosphere.

Rocket Lab’s groundbreaking Electron rocket is being upgraded for reusability and its next launch is set to debut some new hardware. (Rocket Lab)

The company’s tenth successful launch dubbed “Running Out of Fingers” in December of 2019 was not only successful because it delivered and deployed the payload, but it was also the first time that Electron’s first stage first made it safely through the wall intact. Unlike SpaceX’s Falcon 9 that slows during descent with a series of engine burns, Rocket Lab’s Electron orients itself for the right “angle of attack” to slow down during re-entry.

The first stage of Electron has undergone a number of block upgrades to enable re-entry in one piece. The tenth mission featured the use of the upgraded Electron booster equipped with guidance and navigation hardware, as well as, a reaction control system (RCS) to gently control and reorient the first-stage during re-entry. The RCS was able to keep the booster adequately oriented and slowed it to under 900 kilometers per hour (560mph) for a controlled sea-level impact. The following eleventh mission dubbed “Birds of a Feather” in February 2020, also featured a successful controlled descent of the upgraded Electron first stage.

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The final step in slowing the Electron down enough to be recovered by a grappling hook suspended by a helicopter was to develop and test a parachute system. Beck posted a teaser of the prototype parachute on Twitter in early February promising low altitude drop tests to follow soon after. Rocket Lab stated that the successful “mid-air recovery” test occurred weeks prior to the now mandated “Safer at Home” orders given in New Zealand amid the global COVID-19 pandemic.

As reported by Michael Sheetz of CNBC, Rocket Lab will continue to test recovery efforts on an undisclosed mission scheduled for later this year. That test will exercise Electron’s RCS block upgrades and parachute system to a greater extent to slow the booster to a point of survivability upon impact with the water – a speed of about 8kilometers per hour (5mph).

Like SpaceX, Rocket Lab targets a reduction of launch costs and an increase in launch capabilities with full first-stage reusability. The dedicated launcher of small satellites also strives to further open access to space for the rapidly expanding small satellite market.

Currently, Rocket Lab has two operational launch pads, one on New Zealand’s Mahia Penninsula and another at the Mid-Atlantic Regional Spaceport at NASA’s Wallops Flight Facility in Virginia. Later this year a second location on New Zealand’s Mahia Penninsula will come online drastically increasing Rocket Lab’s launching capabilities.

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SpaceX Starship Flight 13 aborted at Zero and Musk just told us what broke

Four Raptor engines failed to ignite at T-zero, forcing SpaceX to scrub Starship Flight 13 Thursday.

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SpaceX scrubbed the Starship Flight 13 launch attempt Thursday evening at the last possible moment, after four of the Super Heavy booster’s 33 Raptor 3 engines failed to ignite during the startup sequence. The 90-minute window had opened at 6:45 p.m. EDT from Starbase in Boca Chica, Texas, and the countdown had proceeded without issue all day, with more than 11.5 million pounds of liquid methane and liquid oxygen being fully loaded into the rocket before the automated abort triggered. SpaceX’s launch directors posted on X, “Standing down from today’s flight test attempt,” and shut down the livestream shortly after.

Musk confirmed the root cause within hours. “Some of the engines didn’t start, triggering an automatic launch abort,” he wrote on X. “To be confident of a good flight, 2 Raptors will be removed and replaced. Most probable launch timing is early next week.” SpaceX engineers began draining propellant tanks immediately and Booster 20 was rolled back to its hangar for inspection.

SpaceX comes with a slew of changes for Starship Flight 13

 

The timing adds a layer of significance that did not exist during any of the previous 12 Starship flights. This is the first time SpaceX has attempted to launch Starship since the company made its stock market debut in June, listing under ticker SPCX at $135 per share. Public investors are now watching every Starship outcome in real time, and a last-second abort carries more visibility than it would have six months ago.

Flight 13 was designed to be one of the most consequential tests in the program’s history. It was set to carry 20 Starlink V3 satellites, the first operational payload Starship has ever attempted to deploy. Six of those satellites carried external cameras to photograph Starship’s heat shield from the outside during flight, which would act as a self-inspection approach SpaceX has never attempted before. The mission also needed to complete a Raptor engine relight in space, a step SpaceX skipped on Flight 12 in May after losing an engine during ascent. That Flight 12 booster also flipped 90 degrees off course during its boostback burn when five engines failed to reignite.

SpaceX has not announced an official next launch date. Musk’s “early next week” window points to July 21 or 22 at the earliest, pending the engine swap and a return to the pad.

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Elon Musk secretly acquires $1B energy company to power the AI future

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Gage Skidmore, CC BY-SA 4.0 , via Wikimedia Commons

Elon Musk flew under the radar with his recent purchase of a $1 billion energy company, according to Federal Trade Commission (FTC) documents.

Transaction number 202612350 listed Tesla and SpaceX frontman Elon Musk as the acquiring party and CF APR Super Holdings LLC as the seller, with New APR Energy, LLC as the acquired entity. The deal, which closed without public announcement, came to light on May 14.

Analysts inferred the deal’s scale from minority stakeholder disclosures, including one report of a 5 percent interest sold for approximately $50.4 million. Fortress Investment Group had purchased APR’s assets in late 2024, rebranded the operation as New APR Energy, and subsequently transferred ownership to Musk.

APR Energy specializes in rapidly deployable power infrastructure. The company maintains one of the world’s largest fleets of mobile gas and diesel turbines, with more than 1.1 gigawatts of generation capacity. Its modular units, which are often trailer-mounted, enable turnkey installations ranging from 20 MW to over 500 MW.

Elon Musk admits he was ‘clearly wrong’ about Anthropic

APR provides full engineering, procurement, construction, operation, and maintenance services for behind-the-meter power plants, serving everything from data centers, utilities, and industrial clients.

The firm has expanded aggressively to meet surging demand, recently adding turbines and deploying over 100 MW for a major AI hyperscaler. Its solutions bridge critical gaps where grid interconnections face delays of two to five years, according to Yahoo.

The acquisition means something more for Musk. As he continues to expand projects in artificial intelligence, especially xAI, his AI venture, there is a greater need to supply energy-intensive supercomputing clusters, including the Colossus project, with what they need: reliable and high-capacity power.

Ownership of APR provides immediate access to flexible generation assets that can be deployed adjacent to data centers, reducing dependence on a strained infrastructure. It also complements Tesla’s energy storage business, so Musk will be able to pull from his own entities to address the rapid scaling demands of AI training and compute.

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Tesla has to fix a big problem with its old headlights, NHTSA says

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tesla model 3 first generation headlight
Credit: Tesla Asia/Twitter

Tesla had a petition protesting a recall to fix a potential issue with 2017-2023 Model Y and Model 3 vehicles’ headlights was denied, as the National Highway Traffic Safety Administration (NHTSA) disagreed with the company’s opinion of things.

The recall covers approximately 19,917 Model Y and Model 3 vehicles built from 2017 to 2023. Tesla initially submitted a noncompliance report for the headlights on these vehicles on March 15, 2024. Tesla then petitioned for an exemption from the fix, which violated FMVSS No. 108 (40 CFR 571.108), arguing that the “noncompliance is inconsequential as it relates to motor vehicle safety.

The NHTSA disagreed, stating that Tesla’s conclusion that the headlights do not increase any risk was not an opinion it shared. The agency said it disagreed with Tesla’s assumption that glare is not increased to surrounding traffic. This issue could be highlighted even more in certain weather conditions.

Tesla will be required to remedy the issue, the NHTSA ruled:

“In consideration of the foregoing, NHTSA has decided that Tesla has not met its burden of persuasion that the subject FMVSS No. 108 noncompliance is inconsequential to motor vehicle safety. Accordingly, Tesla’s petition is hereby denied, and Tesla is consequently obligated to provide notification of and free remedy for that noncompliance under 49 U.S.C. 30118 and 30120.”

The issue here appears to be the angle of the headlights and the brightness they emit during operation. The NHTSA report states that:

“Tesla’s headlamp supplier, Marelli Automotive Lighting, tested 25 right-hand and 25 left-hand lamps, and for this sample, found the maximum photometric intensity measured in the 10°U to 90°U and 90°L to 90°R zone was between 136.2 cd and 230.1 cd for the right-hand lamps and between 117.5 cd and 160.3 cd for the left-hand lamps. According to Tesla, these tests revealed that the photometric intensity of the right-hand and left-hand headlamp lower beam on the subject vehicles may measure as much as 230.1 cd in the 10°U to 90°U and 90°L to 90°R zone, exceeding the maximum photometric intensity by 105.1 cd. Additionally, Tesla states that a left-hand lamp tested by a Transport Canada recognized laboratory measured a maximum of 171.27 cd in the 10°U to 90°U and 90°L to 90°R zone. Despite these measurements exceeding the allowed photometric maximum of 125 cd, Tesla believes that the subject noncompliance is inconsequential to motor vehicle safety.”

Tesla also argued at some points that the headlights had not been deemed responsible for any complaints, accidents, or injuries related to the noncompliance.

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