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SpaceX's in-flight rocket engine failure threatens NASA astronaut launch debut

Falcon 9 punches through Max Q - peak aerodynamic stress - during its Starlink L6 launch. The booster did not survive the mission. (Richard Angle)

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An in-flight rocket engine failure during SpaceX’s March 18th Starlink launch could pose a threat to the company’s imminent NASA astronaut launch debut according to a statement provided by the space agency yesterday.

SpaceX and NASA are currently working around the clock to prepare a Falcon 9 rocket and Crew Dragon spacecraft for the company’s inaugural astronaut launch, a flight known as Demonstration Mission 2 (Demo-2/DM-2). All launch vehicle and spacecraft hardware – including booster B1058, an expendable upper stage, a spacecraft trunk, and the Crew Dragon capsule itself – are already believed to be at SpaceX’s Florida launch and processing facilities.

Prior to March 18th, the biggest gating items were believed to be a few final parachute tests and a whole lot of paperwork and reviews, as well as some important but less showstopping astronaut training. Unfortunately, SpaceX has suffered two unforeseen issues of varying severity in the last few days, both of which are now all but guaranteed to impact Crew Dragon’s astronaut launch debut schedule.

“According to the CCtCap contracts, SpaceX is required to make available to NASA all data and resulting reports. SpaceX, with NASA’s concurrence, would need to implement any corrective actions found during the investigation related to its commercial crew work prior to its flight test with astronauts to the International Space Station. NASA and SpaceX are holding the current mid-to-late May launch timeframe, and would adjust the date based on review of the data, if appropriate.”

NASA — March 25th, 2020

B1048 lifted off for the fifth and final time on March 18th, 2020. (Richard Angle)

On March 18th, less than three minutes after liftoff and shortly before stage separation was scheduled, Falcon 9 booster B1048 – on its historic fifth launch attempt – suffered an engine failure visible on SpaceX’s official webcast. By all appearances, Falcon 9’s autonomous flight computer accounted for the engine’s failure, shutdown, and the resultant loss of thrust by burning B1048’s eight remaining engines for several seconds longer than planned.

Falcon 9 B1048 is pictured during launch, one frame (~0.05s) before it suffered an engine failure. (SpaceX)
The first frame of the off-nominal event. The extremely unusual flare is very likely one of Falcon 9’s nine Merlin 1D engines exploding during flight. (SpaceX)

While that extra few seconds of burn time likely ensured that the rocket’s upper stage was able to make it to the correct orbit after stage separation, roughly five minutes after B1048’s extremely rapid engine failure, contact was lost. For the first time ever, there were no landing burn-related call-outs from SpaceX launch operators, the first sign that something was seriously wrong. A few minutes later, SpaceX’s webcast hosts acknowledged that the booster had been lost, perhaps lacking the propellant it needed to attempt a landing.

For reference, Merlin 1D engines likely consume some ~270 kg (600 lb) of fuel each second. Falcon 9’s landing propellant reserves are believed to be on the order of 50+ metric tons (110,000 lb). Excluding the failed engine, eight Merlin 1Ds burning at full thrust for an additional 5 seconds would consume 20% of the propellant needed for landing; 10 seconds and it would use 40%.

The anomaly was Merlin 1D engine’s first in-flight failure ever. The 2012 failure of one of an original Falcon 9 V1.0’s rocket’s nine Merlin 1C engines is SpaceX’s only other in-flight failure.

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It’s likely that B1048’s engine failure was primarily related to the fact that the booster was SpaceX’s pathfinder for a fifth-flight reusability milestone, making it the most reused rocket booster ever launched. NASA currently requires all of its Crew Dragon missions to launch on new Falcon 9 rockets, hopefully mitigating direct corollaries between the Starlink L6 anomaly and astronaut launches. Regardless, the space agency says that the company will now have to complete its internal failure review and implement necessary hardware, software, or rule changes before it’s allowed to launch NASA astronauts.

In a major twist, NASA has effectively confirmed that SpaceX will become the first private company in history to launch astronauts into orbit. (SpaceX)
Technicians prepare SpaceX’s Crew Dragon Demo-2 spacecraft for its historic launch debut in February 2020. (SpaceX)

That investigation could take a matter of weeks, possibly even less, but it’s entirely possible that it could take months – let alone fixing the problems that allowed the in-flight Merlin 1D engine failure to happen in the first place. Ultimately, it will almost certainly make even the first flights of Falcon 9 and Heavy rocket boosters safer, but it could substantially delay SpaceX’s Demo-2 astronaut launch debut. Still targeted no earlier than (NET) mid-to-late May 2020, it’s safe to say that it’s reasonable to expect that schedule to slip over the next 4-6 weeks. Stay tuned for updates.

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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Cybertruck

Tesla upfitter offers to keep Cybertruck alive

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Credit: Unplugged Performance

A Tesla upfitter has offered to take over Cybertruck lines from the company in a last-ditch effort to save the all-electric pickup from being completely canceled in the middle of 2027.

Unplugged Performance, the Hawthorne, California-based Tesla aftermarket specialist, has publicly offered to take over Cybertruck production from Tesla, funding the effort “through a consortium of investors.”

The proposal comes as Tesla prioritizes its Cybercab Robotaxi program and prepares to wind down Cybertruck assembly at Gigafactory Texas around mid-2027.

Founded in 2013 by Ben Schaffer and located adjacent to Tesla’s Design Studio and SpaceX, Unplugged Performance has become a leading provider of premium upgrades for Tesla vehicles, including extensive Cybertruck packages under its UP INVINCIBLE line.

Through its UP.FIT division, the company has also developed purpose-built police and fleet versions of the Cybertruck, including deliveries to agencies such as the Las Vegas Metropolitan Police Department.

In an X post on Tuesday, Unplugged said:

“An open offer to Tesla: We fully support putting Cybercab first, and we’d be glad to take the Cybertruck line off your hands. We’d fund it with a consortium of investors and run it at no cost to Tesla’s floor space, headcount, or focus. All of that goes to Cybercab. Cybercab gets first call on battery cells too. We’ll wait our turn. Tesla gains incremental profit: a license fee, plus FSD and Robotaxi network revenues on every vehicle built. We’d build the Cybertruck, a three-row CyberSUV, and an unmanned CyberCargo hauler. More autonomous miles, across every surface of this planet and beyond. Worth a conversation?”

The arrangement would free Tesla resources and manufacturing capacity for Cybercab while allowing continued production of the stainless-steel pickup and expanded variants. Unplugged Performance indicated it would wait for battery cells after Cybercab needs are met and would generate ongoing revenue for Tesla through licensing and software/network services on the vehicles it produces.

Following strong initial interest, Unplugged Performance posted a follow-up inviting potential investors and strategic partners to email cyber@unpluggedperformance.com. The company clarified that the outreach is solely to gauge interest and does not constitute an offer to sell securities or acceptance of funds at this stage.

The proposal arrives shortly after Elon Musk indicated that Cybertruck production in Texas would be phased out by roughly the middle of 2027 to expand Cybercab output.

Whether Tesla engages with the offer remains to be seen, but the public overture highlights both the aftermarket specialist’s deep experience with the Cybertruck platform and the growing focus on autonomy within Tesla’s manufacturing plans.

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Elon Musk

Elon Musk says Tesla Cybercab future is ‘obvious to anyone with eyes and a brain’

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Elon Musk said the Tesla Cybercab will perform “a majority of all passenger miles” where it is allowed to operate and that point is “obvious to anyone with eyes and a brain.”

Musk used the point to double down on the company’s decision to ax the cult-favorite Cybertruck, as its production space will be removed and transitioned into additional Cybercab lines. The move has catalyzed a polarizing conversation on whether its right or wrong.

Whatever side you are on — it’s happening.

Regardless, Musk seems to be getting to the point that he is done talking about the choice. At some point, you have to think that this was truly a difficult decision for him and the company as well, and this is not something he took lightly. In fact, he’s probably a little bit disappointed with it, too.

But the point remains that the Cybertruck is gone. Musk’s focus is purely on developing an autonomous platform that the world will utilize for transportation, and he’s telling you that anyone “with eyes and a brain” can see it:

Tesla is betting that all of its passengers in the future will be okay with not owning their own personal cars and will be fine with ride-hailing for the rest of their lives. Every dinner, every errand, every trip to the airport and transportation thereafter, will all be operated by ride-sharing, and in Tesla’s perfect world, it will happen in a Cybercab.

As of now, Cybercab is only active in Austin, but it has been spotted all over the country with a driver behind the wheel in those prototypes. In Austin, the car has no steering wheel or pedals for people to control the vehicle.

The Cybertruck dilemma is one that has truly come across the entire Tesla community and while it seems to be a great idea to keep it because people love it, the business side of things is steering Musk and Tesla in another direction.

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Tesla slims Cybertruck offerings to only its most expensive trim

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Credit: u/dregonzz/Reddit

Tesla has slimmed its Cybertruck offerings to offer only its most expensive trim: the Cyberbeast.

After announcing that the Cybertruck would no longer be produced and the company would wind down manufacturing sometime in the middle of 2027, Tesla started to eliminate some of the configurations offered to customers.

Now, only one remains: the $109,990 Cyberbeast. This is truly what seems like Tesla’s last effort to deter any remaining orders from coming in: eliminate the cheap trims and leave only the high-dollar vehicle within the lineup of Cybertruck options.

Those who want to take advantage of this last-ditch opportunity to own Tesla’s symbolic pickup have to pay to play.

Tesla says the reason for the wind down is truly because of Cybercab and its importance to the future.

Despite cries for Tesla to continue production of the pickup, Musk says it is too difficult to ramp a high-volume line instead of ending the truck altogether. He also says Cybercab is what will take passengers around for the “majority of all miles in any jurisdiction where it is not prohibited by law.”

Tesla is going all in on autonomy, and that’s never been a secret. But the commitment to a two-door, two-seat Cybercab truly limits people from having options for labor or hobbies. It also limits people from having their entire family in a single car.

Parents with even a single child will be required to take multiple vehicles if Cybercab is truly the only option Tesla plans to have.

Elon Musk keeps justifying Tesla Cybertruck’s cancelation, but it’s confusing

Tesla has stated the Robovan will also be in production eventually, but it still does not seem like the most ideal vehicle to own. It seems like it is geared more toward commercial uses, but Tesla might have something in the pipeline for families.

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