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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%.

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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.

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.

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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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Elon Musk reveals when SpaceX will perform first-ever Starship catch

“Starship catch is probably flight 13 to 15, depending on how well V3 flights go,” Musk said.

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August 28, 2025

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Credit: SpaceX

Elon Musk revealed when SpaceX would perform the first-ever catch attempt of Starship, its massive rocket that will one day take life to other planets.

On Tuesday, Starship aced its tenth test flight as SpaceX was able to complete each of its mission objectives, including a splashdown of the Super Heavy Booster in the Gulf, the deployment of eight Starlink simulators, and another splashdown of the ship in the Indian Ocean.

It was the first launch that featured a payload deployment:

SpaceX Starship Flight 10 was so successful, it’s breaking the anti-Musk narrative

SpaceX was transparent that it would not attempt to catch the Super Heavy Booster, something it has done on three previous occasions: Flight 5 on October 13, 2024, Flight 7 on January 16, and Flight 8 on March 6.

This time, it was not attempting to do so. However, there are bigger plans for the future, and Musk detailed them in a recent post on X, where he discussed SpaceX’s plans to catch Starship, which would be a monumental accomplishment.

Musk said the most likely opportunities for SpaceX to catch Starship itself would be Flight 13, Flight 14, and Flight 15, but it depends on “how well the V3 flights go.”

The Starship launched with Flight 10 was a V2, which is the same size as the subsequent V3 rocket but has a smaller payload-to-orbit rating and is less powerful in terms of initial thrust and booster thrust. Musk said there is only one more V2 rocket left to launch.

V3 will be the version flown through 2026, as V4, which will be the most capable Starship build SpaceX manufactures, is likely to be the first company ship to carry humans to space.

Musk said that SpaceX planned to “hopefully” attempt a catch of Starship in 2025. However, it appears that this will likely be pushed back to 2026 due to timing.

SpaceX will take Starship catch one step further very soon, Elon Musk confirms

SpaceX would need to launch the 11th and 12th test flights by the end of the year in order to get to Musk’s expected first catch attempt of Flight 13. It’s not unheard of, but the company will need to accelerate its launch rate as it has only had three test flights this year.

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Tesla Robotaxi rival Waymo confirms massive fleet expansion in Bay Area

New data from the California Public Utilities Commission (CPUC) said Waymo had 1,429 vehicles operating in California, and 875 of them were “associated with a terminal in San Francisco,” according to The SF Examiner.

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3 hours ago

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August 28, 2025

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Credit: Uber

Tesla Robotaxi rival Waymo has confirmed that it has expanded its fleet of driverless ride-sharing vehicles in the Bay Area of California massively since its last public disclosure.

It is perhaps one of the most important metrics in the race for autonomous supremacy, along with overall service area. Tesla has seemed to focus on the latter, while expanding its fleet slowly to maintain safety.

Waymo, on the other hand, is bringing its fleet size across the country to significant levels. In March, it told The SF Examiner that there were over 300 Waymos in service in the San Francisco area, which was not a significant increase from the 250 vehicles on the road it reported in August 2023.

In May, the company said in a press release that it had more than 1,500 self-driving Waymos operating nationwide. More than 600 were in the San Francisco area.

Tesla analyst compares Robotaxi to Waymo: ‘The contrast was clear’

However, new data from the California Public Utilities Commission (CPUC) said Waymo had 1,429 vehicles operating in California, and 875 of them were “associated with a terminal in San Francisco,” according to The SF Examiner.

CPUC data from March 2025 indicated that there were a total of 1,087 Waymo vehicles in California, with 762 located in San Francisco. Some were test vehicles, others were deployed to operate as ride-sharing vehicles.

The company’s August update also said that it deploys more than 2,000 commercial vehicles in the United States. That number was 1,500 in May. There are also roughly 400 in Phoenix and 500 in Los Angeles.

While Waymo has done a good job of expanding its fleet, it has also been able to expand its footprint in the various cities it is operating in.

Most recently, it grew its geofence in Austin, Texas, to 90 square miles. This outpaced Tesla for a short period before the company expanded its Robotaxi service area earlier this week to roughly 170 square miles.

Tesla one-ups Waymo once again with latest Robotaxi expansion in Austin

The two companies have drastically different approaches to self-driving, as Waymo utilizes LiDAR, while Tesla relies solely on cameras for its suite. Tesla CEO Elon Musk has made no mistake about which he believes to be the superior solution to autonomy.

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Tesla launches Full Self-Driving in a new region

Today, Tesla launched Full Self-Driving in Australia for purchase by car buyers for $10,100, according to Aussie automotive blog Man of Many, which tried out the suite earlier this week.

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August 28, 2025

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Credit: Tesla

Tesla has launched its Full Self-Driving suite in a new region, marking a significant step in the company’s progress to expand its driver assistance suite on a global scale.

It is also the first time Tesla has launched FSD in a right-hand-drive market.

Today, Tesla launched Full Self-Driving in Australia for purchase by car buyers for $10,100, according to Aussie automotive blog Man of Many, which tried out the suite earlier this week.

Previously, Basic and Enhanced Autopilot suites were available, but the FSD capability now adds Traffic Light and Stop Sign Control, along with all the features of the previous two Autopilot suites.

It is the first time Tesla has launched the suite by name in a region outside of North America. In China, Tesla has “City Autopilot,” as it was not permitted to use the Full Self-Driving label for regulatory reasons.

However, Tesla still lists Full Self-Driving (Supervised) as available in the U.S., Canada, China, Mexico, and Puerto Rico.

The company teased the launch of the suite in Australia earlier this week, and it appeared to have been released to select media members in the region earlier this week:

Tesla FSD upcoming Australia release seemingly teased bv media

The rollout of Full Self-Driving in the Australian market will occur in stages, as Model 3 and Model Y vehicles with Hardware 4 will receive the first batch of FSD rollouts in the region.

TechAU also reported that “the initial deployment of FSDs in Australia will roll out to a select number of people outside the company, these people are being invited into Tesla’s Early Access Program.”

Additionally, the company reportedly said it is “very close” to unlocking FSD in customer cars:

Each new Tesla sold will also come with a 30-day free trial of the suite.

Australia is the sixth country to officially have Full Self-Driving available to them, following the United States, Canada, China, Mexico, and Puerto Rico.

Here’s the first look at the suite operating in Australia:

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