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SpaceX ships 200th Falcon second stage, highlighting the flip-side of booster reuse

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SpaceX has built and shipped its 200th Falcon second stage, highlighting the often underappreciated rocket’s record of achievement on the ground and in flight.

Approximately 13 years ago, in late 2009 or early 2010, SpaceX shipped the first flightworthy prototype of the first iteration of its Falcon 9 second stage. In June 2010, Falcon 9 lifted off on its inaugural test flight and, with the help of that second stage, successfully launched a boilerplate mockup of Dragon spacecraft into orbit. Since Falcon 9’s surprising inaugural success, SpaceX’s Falcon 9 and Falcon Heavy rockets have launched another 187 times for a total of 188 launches and 189 assembled rockets. Every one of those launches has required a new second stage, and all but one (Crew Dragon’s In-Flight Abort test) required a new Merlin Vacuum engine.

While SpaceX is most famous for the successful realization of rapidly reusable Falcon boosters, the company’s overall success is also inextricably linked to Falcon second stages, which are and always will be expended after every launch. For every spectacular Falcon booster landing or reuse record, a Falcon second stage either unceremoniously burns up in Earth’s atmosphere or finds itself stranded in orbit. As a result, even as SpaceX’s reusability has allowed it to launch more than ever before with a fleet of just 10-20 Falcon boosters, the company has had to expand the production of Falcon second stages extraordinary levels.

SpaceX just completed its 188th Falcon 9/Heavy launch, so the 200th flightworthy second stage and Merlin Vacuum (MVac) engine are probably scheduled to launch sometime in January 2023. In the last 365 days, SpaceX’s Falcon rockets have completed 59 successful orbital launches. Every launch has required a new second stage, so SpaceX, on average, has consistently built, shipped, and tested a new Falcon second stage every 6.2 days for more than a year.

Thanks to SpaceX’s record-breaking 2022 launch cadence, which has resulted in Falcon 9 launching more in one calendar year than any other rocket in history, the Falcon second stage has likely become the most-produced orbital rocket stage in decades. Barring surprises, SpaceX is on track to achieve CEO Elon Musk’s goal of 60 Falcon launches in 2022. But SpaceX isn’t done yet, and CEO Elon Musk says that the company is targeting “up to 100 launches” in 2023. After nearly doubling between early and late 2021, that will require Falcon second stage production to increase another ~67% year-over-year.

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In its 12.5-year career, Falcon 9 has suffered three failures. In October 2012, on its third launch, one of Falcon 9’s nine Merlin 1C booster engines failed in flight. The main mission – a Dragon cargo mission to the International Space Station – was saved by the second stage, which autonomously compensated for the lost performance, but a secondary payload (Orbcomm’s first OG2 satellite prototype) was lost as a result. In June 2015, a faulty strut inside Falcon 9’s second stage caused a helium pressure vessel to break loose and rupture, destroying the rocket mid-flight. And in September 2016, during a prelaunch static fire test, a similar pressure vessel inside an upgraded Falcon 9’s second stage spontaneously sparked, causing an explosion that destroyed the rocket while it was still on the ground.

As a result, while problems with Falcon second stages have technically caused both of Falcon 9’s only catastrophic failures, it’s still true that a free-flying Falcon second stage has never failed in flight. The same is true for the second stage’s Merlin Vacuum engine: over hundreds of burns and more than 70,000 seconds of operation, MVac has never failed in flight.

SpaceX announced the completion of its 100th MVac engine in April 2020, which means that it took ~130 months to build the first 100 and ~30 months to build the next 100. (SpaceX)

After Falcon 9’s successful November 3rd, 2022 launch of the Eutelsat Hotbird 13G communications satellite, SpaceX’s Falcon rocket family has completed 160 launches without failure, arguably making it the most reliable rocket family in history. To achieve that feat with its partially-reusable Falcon 9 and Falcon Heavy rockets, SpaceX has had to master reusable and expendable orbital rockets to a degree that only a few other companies or space agencies in history can claim to have matched or exceeded, and that none have achieved simultaneously.

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 launches new loaner program that owners will love

Tesla is now giving owners the opportunity to rent a vehicle from them, and it includes a few very attractive features that will have you second-guessing another loaner from insurance.

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Credit: Tesla

Tesla has launched a new loaner program that owners will love, as it resolves some concerns over a replacement vehicle while it is being repaired.

Earlier this week, Tesla launched the option to rent a Tesla loaner vehicle for just $45 per day if your vehicle is in Collision Repair. Collision repairs did not formerly warrant the issuance of loaner vehicles, as the insurance provider of the car owner would provide transportation arrangements.

Tesla is now giving owners the opportunity to rent a vehicle from them, and it includes a few very attractive features that will have you second-guessing another loaner from insurance.

The Tesla you rent while your car is in collision repair will come with free Full Self-Driving, free Supercharging, and free toll coverage, no small print included.

All things considered, this is a great deal for those who require a car for transportation while their car is being repaired.

The cost of Supercharging and Full Self-Driving alone would warrant the $45 per day price tag. Add in the tolls for those who commute on turnpikes for work or are planning an extensive trip that would require it, and it truly becomes an even more attractive deal.

Tesla has done a good job at improving its Service division over the past few years, and it truly needed it. In hopes of launching an F1-style service experience, Tesla started doing away with some of its perks, including loaner vehicles for single-day visits and even Uber credits.

Tesla’s ‘F1’ Service strategy eliminates same-day loaner vehicles, Uber credits

However, it has listened to the complaints of its owners and tried to cater an experience that is more advantageous and less of a hassle. It’s already made tremendous steps in the past few years, and this is the icing on the cake.

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SpaceX Starship Flight 10: What to expect

SpaceX implemented hardware and operational changes aimed at improving Starship’s reliability.

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Credit: SpaceX

SpaceX is preparing to launch the tenth test flight of its Starship vehicle as early as Sunday, August 24, with the launch window opening at 6:30 p.m. CT. 

The mission follows investigations into anomalies from earlier flights, including the loss of Starship on its ninth test and a Ship 36 static fire issue. SpaceX has since implemented hardware and operational changes aimed at improving Starship’s reliability.

Booster landing burns and flight experiments

The upcoming Starship Flight 10 will expand Super Heavy’s flight envelope with multiple landing burn trials. Following stage separation, the booster will attempt a controlled flip and boostback burn before heading to an offshore splashdown in the Gulf of America. One of the three center engines typically used for landing will be intentionally disabled, allowing engineers to evaluate whether a backup engine can complete the maneuver, according to a post from SpaceX.

The booster will also transition to a two-engine configuration for the final phase, hovering briefly above the water before shutdown and drop. These experiments are designed to simulate off-nominal scenarios and generate real-world data on performance under varying conditions, while maximizing propellant use during ascent to enable heavier payloads.

Starship upper stage reentry tests

The Starship upper stage will attempt multiple in-space objectives, including deployment of eight Starlink simulators and a planned Raptor engine relight. SpaceX will also continue testing reentry systems with several modifications. A section of thermal protection tiles has been removed to expose vulnerable areas, while new metallic tile designs, including one with active cooling, will be trialed.

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Catch fittings have been installed to evaluate their thermal and structural performance, and adjustments to the tile line will address hot spots observed on Flight 6. The reentry profile is expected to push the structural limits of Starship’s rear flaps at maximum entry pressure.

SpaceX says lessons from these tests are critical to refining the next-generation Starship and Super Heavy vehicles. With Starfactory production ramping in Texas and new launch infrastructure under development in Florida, the company is pushing to hit its goal of achieving a fully reusable orbital launch system.

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Elon Musk takes aim at Bill Gates’ Microsoft with new AI venture “Macrohard”

It is quite an appropriate name for a company that’s designed to rival Microsoft.

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Credit: xAI/X

Elon Musk has set his sights on Microsoft with a new company called “Macrohard,” a software venture tied to his AI startup, xAI. 

Musk described the project as a “purely AI software company” that’s designed to generate hundreds of specialized coding and generative AI agents that could one day simulate products from companies like Microsoft entirely through artificial intelligence.

Macrohard‘s Purpose

Musk announced Macrohard on Friday, though xAI had already registered the trademark with the US Patent Office a few weeks ago, as noted in a PC Mag report. Interestingly enough, this is not the first time that Musk has mentioned such an initiative.

Just last month, he stated that xAI was “creating a multi-agent AI software company, where Grok spawns hundreds of specialized coding and image/video generation/understanding agents all working together and then emulates humans interacting with the software in virtual machines until the result is excellent.”

At the time, Musk stated that “This is a macro challenge and a hard problem with stiff competition,” hinting at the venture’s “Macrohard” moniker. A few years ago, Musk also posted “Macrohard >> Microsoft” on X. 

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Powered by xAI and Colossus

Macrohard appears to be closely linked to xAI’s Colossus 2 supercomputer project in Memphis. Musk has confirmed plans to acquire millions of Nvidia GPUs, joining rivals such as OpenAI and Meta in a high-stakes race for AI computing power. Colossus is already one of the most powerful supercomputer clusters in the world, and it is still being expanded.

xAI is only a couple of years old, having been founded in March 2023. During its Engineering Open House event in San Francisco, Elon Musk highlighted that the company’s speed will be its primary competitive edge. “No SR-71 Blackbird was ever shot down and it only had one strategy: to accelerate,” Musk said.

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