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SpaceX’s Mr. Steven preparing for first Falcon 9 fairing catch attempt in months
SpaceX recovery vessel Mr. Steven has spent the last several weeks undergoing major refits – including a new net and arms – and testing the upgraded hardware in anticipation of the vessel’s first fairing catch attempt in more than four months.
Required after a mysterious anomaly saw Mr. Steven return to Port in February sans two arms and a net, the appearance of a new net and arms guarantees that SpaceX is still pursuing its current method of fairing recovery. Above all else, successfully closing the loop and catching fairings could help SpaceX dramatically ramp its launch cadence and lower costs, especially critical for the affordable launch of the company’s own Starlink satellite constellation.
The Saga of Steven
For a few months of 2019, it was entirely conceivable that SpaceX had all but given up on catching Falcon fairings, having spent the better part of 2018 without a single success during both post-launch and experimentally controlled catch attempts. Admittedly, a year may feel like a huge amount of time, but SpaceX has demonstrated just how hard the reliably successful recovery of orbital-class rocket hardware really is.
Depending on how one examines the history of Falcon 9, it took SpaceX anywhere from ~30 and ~70 months and either 7 or 9 failed recovery attempts before the first Falcon 9 booster successfully landed in December 2015. Excluding helicopter-based fairing drop tests, Mr. Steven and SpaceX’s fairing recovery team have made five attempts to catch fairings in the vessel’s net after Falcon 9 launches. All have been unsuccessful, with the closest miss reportedly landing in the Pacific Ocean just 50 meters away from Mr. Steven’s massive net.
In January 2019, Mr. Steven sailed ~8000 km (5000 mi) from Port of Los Angeles to Port Canaveral, passing through the Panama Canal. For unknown reasons, during a trip out to sea to catch a Falcon 9 fairing in February, Mr. Steven abruptly turned around early and arrived in port missing two of four arms, four of eight booms, and the entirety of its custom net. The remaining arms/booms were removed and the vessel spent roughly three months docked with just a handful of excursions.
In late May, technicians rapidly installed new arms and booms, as well as a new (and blue) net, bringing about the end of months of inactivity. Mr. Steven has yet to venture beyond the safety of Port Canaveral since its new ‘catcher’s mitt’ was installed, but SpaceX has been testing the new setup by repeatedly lowering a Falcon fairing half into the net. It’s too early to raise expectations but it seems plausible that the iconic recovery vessel will be ready to attempt its first fairing catch in ~4 months as part of Falcon Heavy’s next scheduled launch, currently NET June 22.
A challenger approaches…
Although Mr. Steven’s prospects look better than they have in months, SpaceX’s fairing recovery engineers and technicians have not been sitting on their hands. Begun as a check against the growing possibility that reliably catching fairings in a (relatively) small net is just too difficult to be worth it, SpaceX has been analyzing methods of reusing fairings without Mr. Steven. Most notably, despite the failure to catch fairings out of the air, the fairing halves themselves – relying on GPS-guided parafoils – have proven to be capable of reliably performing gentle landings on the ocean surface.
This consistently leaves the fairings intact and floating on the ocean but at the cost of partial saltwater immersion and exposure to surface-level sea spray and waves. At least in today’s era of highly complex large satellites, customers typically demand that payload fairings (like Falcon 9’s) offer a clean room-quality environment once the satellite is encapsulated inside. Sea water is full of salt, organic molecules, and water, all three of which do not get along well with extremely sensitive electronics. The whole purpose of recovering and reusing fairings is to make their reuse more efficient and less expensive than simply building a new fairing. The task of cleaning composite structures to clean room-standards after salt water exposure and immersion tends to be less than friendly to both aspirations.
According to SpaceX CEO Elon Musk, however, that challenge may be distinctly solvable and could even be easier than the Mr. Steven approach. After Falcon Heavy’s commercial Arabsat 6A launch debut in April 2019, Musk again confirmed that SpaceX would be ready to test that alternate method of fairing reuse very soon and plans to do so on an “internal” (i.e. Starlink) launch later this year. As noted below, this is helped by the fact that SpaceX’s internally-developed Starlink satellites apparently have no need for the acoustic insulation panels that normally protect sensitive spacecraft from the brutal acoustic environment produced by rockets while still in Earth’s atmosphere.
For fairing reusability, the lack of those panels is just one less thing to have to worry about cleaning or replacing. Intriguingly, it’s easy to imagine that – much like SpaceX has apparently designed Starlink satellites to be resistant to intense acoustic environments – the company could have also required that they be tough enough to tolerate a less-than-pristine fairing environment. With that approach, SpaceX could continue to build new fairings for every customer launch, entirely amortizing their production cost before transferring the ‘dirty’, flight-proven fairings to internal Starlink launches.
In essence, SpaceX’s customers would quite literally be paying the company to build the very Falcon 9 boosters and fairings it will ultimately use to launch its massive Starlink constellation, requiring hundreds of launches over the next decade. The faster and more efficiently SpaceX can build and launch Starlink, the faster it can develop Starship/Super Heavy and entirely transcend any concerns of salty fairings (let alone expendable upper stages). But in the meantime, Mr. Steven will return to his catching duties and SpaceX will continue to attempt to reuse payload fairings.
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Elon Musk
Tesla shows what Roadster drivers will see on screen before thruster activation
Tesla’s Roadster video reveals a fighter jet inspired cockpit with a 5,500 PSI thruster gauge.
Tesla has given future owners their clearest look yet at the cockpit of its next generation Roadster. In a 34 second video posted to X on Friday afternoon, the company walked through the car’s touchscreen with a caption: “Inspired by fighter jet cockpits, Roadster’s interface was designed around the pilot.”
The clip opens on a black screen with red graphics and a 3D wireframe of the car, which sits beside the Roadster’s squared off yoke. Tapping parts of the model brings up controls for the rear wing, including low drag and high downforce positions, along with a charging page with a charge limit bar and a small music player. A row of tabs along the bottom reads Home, Vehicle, Listen, Climate and Navigate.
Most of the video is spent in Track Mode. The dashboard shows a live circuit map, a list of session lap times, brake and motor temperatures, and pressure and temperature readouts for each tire. A setup page lets the driver pick Auto, Low Drag, High Downforce or Custom aero modes, adjust aero balance and brake balance, and switch stability and traction control off. Along the bottom, a status bar reads “Thruster · 5,500 PSI” next to a “Boost Ready” indicator.
That gauge ties the software to the hardware Tesla showed off near Waco, Texas on October 15. The Thrust and Rocket versions use cold gas thrusters fed by carbon overwrapped pressure vessels, and Tesla lists 0 to 60 mph times of under 0.9 seconds and under 0.59 seconds for them, as Teslarati detailed in its breakdown of the three Roadster configurations. The base Performance car relies on a fan and ground sealing system for grip, and the aero settings on screen match the active wings and suction setup covered in our look at how the Roadster generates downforce.
The Roadster layout is a departure from the rest of Tesla’s lineup. Instead of a map centered screen, the Roadster puts the car itself at the center of the home page, and Tesla’s Roadster page lists two smaller forward displays alongside the main touchscreen. Tesla has not said whether any of the Track Mode telemetry will make its way to the Model 3 Performance or other vehicles.
The interface could still change before deliveries. Elon Musk said at the event that Roadster production will begin in 2028, and Tesla says the flagship Rocket version is not approved for public road use. Reservations are open with a $50,000 payment, while Thrust is listed as a limited release and Rocket is invite only.
Those who want to see the car in person will get their first chance this weekend. The Roadster goes on display in the lobby of the Petersen Automotive Museum in Los Angeles from October 24 to 27, according to Sawyer Merritt, the first time the public will be able to view it up close.
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.
Tesla shows what Roadster drivers will see on screen before thruster activation
Tesla reveals Optimus Academy, where robots teach themselves
