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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.

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.

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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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SpaceX achieves incredible milestone with Starlink program

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Credit: SpaceX

SpaceX has achieved an incredible milestone by launching its 11,000th Starlink satellite into orbit.

This accomplishment occurred during the Starlink Group 17-50 mission, which lifted off on August 19 at 04:01 UTC from Space Launch Complex 4 East at Vandenberg Space Force Base in California.

A Falcon 9 rocket carried 24 Starlink V2 Mini satellites on this flight, successfully deploying them into low Earth orbit approximately one hour after liftoff. The first stage booster, identified as B1097 on its twelfth flight, landed successfully on the droneship Of Course I Still Love You in the Pacific Ocean.

According to tracking data compiled around that date, this deployment brought the total number of Starlink satellites in orbit to just over 11,000.

The Starlink program began with test satellites known as Tintin A and B, launched on February 22, 2018. The first operational batch of 60 Starlink satellites followed on May 24, 2019, when a Falcon 9 rocket lifted off from Cape Canaveral. Those initial satellites marked the start of a rapid expansion that has continued for more than seven years.

SpaceX has conducted hundreds of dedicated Starlink missions since then, routinely launching batches of 20 to 30 satellites at a time using reusable Falcon 9 rockets. By mid-2026, the company had already surpassed 12,000 total satellites launched across all versions, with continuous replacements for units that deorbit as designed to manage space debris.

Looking ahead, SpaceX continues to expand the Starlink constellation to enhance global broadband coverage, capacity, and speed. The network already serves millions of users across more than 160 countries and supports applications ranging from residential internet to maritime, aviation, and emergency services.

Future plans center on next-generation hardware, including larger V3 satellites capable of delivering substantially higher throughput, which require the increased payload capacity of the Starship vehicle currently under development and testing.

In July, SpaceX submitted an application to the Federal Communications Commission seeking authority for a Gen3 constellation of up to 100,000 satellites. These spacecraft would operate in very low Earth orbit shells at altitudes near 325 kilometers and 475 kilometers. The filing requests use of existing Ku, Ka, V, and E band spectrum along with new greenfield W and D band frequencies between 92 and 275 GHz.

SpaceX states that the expanded system aims to deliver multi-gigabit symmetrical broadband to consumers, enterprises, governments, and billions of AI-powered devices worldwide while handling a majority of global internet traffic. Approval and subsequent deployment would depend on regulatory review and the operational readiness of Starship for high-volume launches.

This ambitious scale reflects SpaceX’s ongoing commitment to providing ubiquitous high-speed connectivity from space.

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Tesla is opening Cybercab rides to a select few

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Credit: Tesla

Tesla has opened a new sweepstakes to allow the public to be among the first to take an initial ride in a Cybercab. This all-electric, steering-wheel-less, pedal-less vehicle is the centerpiece of the company’s autonomous ride-hailing platform, Robotaxi.

There are two ways Tesla fans can get to Austin to take part in the first public rides of the Cybercab: by riding on the Robotaxi platform by August 23, or by mailing a very specific entry to their Headquarters at Gigafactory Texas.

Tesla announced the latter portion of the sweepstakes last night:

Tesla will give one entry into the sweepstakes if you mail a 3″ by 5″ piece of paper with your full name, mailing address, telephone number, email address, and date of birth to their address:

Tesla, Robotaxi Sweeps Event

1 Tesla Road,

Austin, TX 78725

There is a limit of one entry per stamped envelope. You can send as many as you’d like, but they must be in separate envelopes.

The company’s unique strategy to give people the opportunity to ride in a Cybercab before pretty much anyone else outside of the company is a hilarious but spot-on representation of how Tesla operates. In classic fashion, they had the perfect response to the event:

Cybercab will launch later this month, it appears, especially as it plans to announce the winners of the sweepstakes on August 25. The car has already been operating internally, as employees have been able to utilize the Cybercab for rides in some capacity, something it announced earlier this month.

Tesla weirdly confirms Cybercab employee rides, a huge milestone

Moving forward, the big goal is to get Cybercab out on the roads and integrated into the public Robotaxi fleet, one that will pick up real-world ride-hailers and give them a ride from Point A to Point B.

No matter which way you cut it, it appears Tesla is close to putting a vehicle with no steering wheel and no pedals on the road to help people travel autonomously.

You can ride along with us in our first Cybercab ride from the We, Robot event in October 2024. The video is embedded below:

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Tesla reveals plans for Robotaxi charging hub in Austin

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Credit: Grok Imagine

Tesla has revealed plans through permit submissions for a massive Robotaxi charging hub in Austin, Texas.

Tesla plans to build the Supercharger hub in multiple phases, with the second phase potentially introducing wireless induction charging, something the company has been developing for the Robotaxi fleet.

Initially, 48 Tesla Robotaxi-geared Superchargers will be built on a lot just across from the St. Elmo, Texas, Service Center. There are about 80 additional spots that will not be impacted by phase 1 of the construction process.

Filings show that the second phase of the project will turn those 80 additional spots into wireless charging for Robotaxi, but it might be an error. The Key Notes state that item 3 is listed as “V4 Charging Cabinet to Support 80 Wireless Chargers in Phase 2. However, the drawings point to V3 Cabinets that are already tied to Superchargers:

There are roughly 128 total spots in the lot, but it is unclear if they will all be used for charging based on what appears to be some sort of typo in the blueprint.

This is among the first Robotaxi charging hubs Tesla has started to develop, as it currently has four others planned throughout various areas: one in Phoenix, one in San Antonio, another in Irving, which will serve the Dallas-Fort Worth area, and another in Las Vegas.

These projects are necessary as Tesla expands its Robotaxi program. Now that preparations have started for the public launch of Cybercab, Robotaxi will likely be expanding aggressively, especially over the next two to three years.

Last night, The Information reported that Tesla was planning to launch Cybercab as soon as the end of August. Hours later, Tesla then announced it was launching a competition for fans to potentially ride in Cybercab during its first public rides.

Tesla Cybercab launch preparations have begun

Tesla’s plan to expand its charging infrastructure in the regions where Robotaxi will initially operate is great preparation for the expanding service. There is still a lot to do, including launching the Cybercab on time.

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