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SpaceX's workhorse Falcon 9 rocket expected to reach major launch milestone in 2020

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Hours after SpaceX launched its 240th new Starlink satellite into orbit, Elon Musk took to Twitter to cryptically reveal that the company’s workhorse Falcon 9 rocket could “reach triple digits this year” if everything goes according to plan.

Designed and built by SpaceX in the late 2000s, the Falcon 9 rocket launched for the first time in June 2010. Developed for the unfathomably low price of $300 million from clean-sheet design to first orbital launch, the original single-core Falcon 9 rocket – known as V1.0 – was about 48m (160 ft) tall, weighed 333 metric tons (735,000 lb) fully fueled, and was capable of launching almost 10.5 metric tons (23,000 lb) into low Earth orbit (LEO). Famously, when provided with Falcon 9’s basic specifications and characteristics, an independent NASA study estimated that the rocket’s development would have cost the agency anywhere from $1.7 billion to $4 billion to design and build.

NASA came to this conclusion in 2011, less than a year after Falcon 9’s first launch, and that the disconnect between the status quo held by NASA and the broader US spaceflight industry and what SpaceX tangibly achieved came to almost perfectly symbolize the rocket’s first six or so years of operations. Although SpaceX stumbled hard with two catastrophic rocket failures in June 2015 and September 2016, the company ultimately picked itself up, learned from those still-agonizing lessons, and has since shaped Falcon 9 into one of the most capable, reliable, reusable, and prolific launch vehicles ever flown. That latter characteristic – the sheer volume of launches Falcon 9 has come to represent – is what CEO Elon Musk was referring to earlier this week.

Specifically, after Wednesday’s flawless launch, Falcon 9 has now launched 80 times in its 9.5-year career, while Starlink V1 L3 marked the workhorse rocket’s 52nd consecutive success of 79 total. Impressively, while those 52 launches represent almost 65% of all of Falcon 9’s missions, SpaceX has dramatically improved the rocket’s reliability and availability over the last few years. In short, Falcon 9 has completed 52 consecutively successful launches in exactly 36 months (January 2017 to January 2020), meaning that nearly two-thirds of its lifetime launches have occurred in less than a third of the time Falcon 9 has been operational.

SpaceX's three surviving thrice-flown Block 5 boosters - B1048, B1049, and B1046 - are pictured here in various stages of recovery. (Teslarati, Pauline Acalin)
Falcon 9 B1048, B1049, and B1046 pictured in various stages of their most recent launches. Together, the three have supported twelve successful orbital-class launches. (Tom Cross & Pauline Acalin)

Put a different way, since the start of 2017, SpaceX has – on average – launched Falcon 9 more than four times (1.4 launches/month) as often as the rocket managed in its first 6.5 years of operations (1 launch every 2.7 months). Tweeting on January 29th, 2020 in response to an overview of the number of launches performed by each operational US rocket, CEO Elon Musk hinted that he believes “Falcon 9 will achieve triple digits” in 2020.

In other words, Musk thinks that SpaceX’s workhorse Falcon 9 rocket will be able to reach more than 100 lifetime launches by the end of 2020 — a feat that will require at least 20 additional Falcon 9 launches over the next 11 months. Speaking hours after SpaceX completed its third launch in January 2020 alone, it’s not hard to imagine – assuming, as Musk did, that “all goes well – that Falcon 9 will manage another 20 launches this year.

Falcon 9 B1049 lifted off for the fourth time with a batch of 60 Starlink satellites on January 7th. (Richard Angle)
Albeit suborbital, Falcon 9 B1046 supported SpaceX’s second launch of 2020 – Crew Dragon’s In-Flight Abort test – on January 19th. (Richard Angle)
Finally, B1051 launched another batch of 60 Starlink satellites on January 29th, likely SpaceX’s last launch of the month. (Richard Angle)

Averaged out, SpaceX has performed a launch every 9.7 days in January. Extrapolated to the rest of the year and assuming no improvement, SpaceX could theoretically perform as many as 37 launches in 2020. It’s worth noting, however, that SpaceX’s third launch of the month was ready for flight as early as January 21st but was delayed more than a week by bad weather – obviously out of the company’s control. Had weather permitted, SpaceX even had a fourth launch planned this month – a Starlink mission that is now expected sometime in early February.

In simple terms, it would take one or several major upsets to prevent Falcon 9 from reaching >100 lifetime launches later this year. Even if every single customer launch abruptly slips into 2021, SpaceX has still said that it has plans for 20-24 dedicated Starlink launches in 2020 alone, potentially singlehandedly carrying Falcon 9 over the 100-launch crest.

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Falcon 9’s next launch – the fourth Starlink v1.0 mission – is currently scheduled no earlier than (NET) early February, followed by another Starlink mission later that month and Cargo Dragon’s final space station resupply mission NET March 2nd.

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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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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.

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The next generation Tesla Roadster’s touchscreen, shown in Tesla’s first official look at the car’s interface. (Credit: Tesla/X)

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.

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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.

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Tesla reveals Optimus Academy, where robots teach themselves

Tesla has begun building production quality Optimus robots in Fremont and revealed its training plan.

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Concept rendering of Tesla Optimus in mass production

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.

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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.

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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.

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Concept rendering of SpaceX Starship landing on the moon via Grok

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.

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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.

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