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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.

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.

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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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Elon Musk

Elon Musk sheds two new bits of detail on Starship after 13th test launch

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Credit: SpaceX

Elon Musk shed two new bits of detail on Starship following its 13th test launch, which was an overwhelming success.

SpaceX launched Starship for the 13th time last Friday after two delays: one on Monday when several Raptor engines did not ignite, and another on Thursday due to unfavorable weather conditions in Starbase, Texas.

The launch was overwhelmingly successful. SpaceX was able to complete a necessary test of the heat shield tiles by increasing the acceleration of Starship from launch throughout the flight; 20 Starlink v3 satellites were released with no issue; the Super Heavy Booster landed safely in the Gulf of America, Ship successfully reignited engines while in space; and it also splashed down without incident in the Indian Ocean.

SpaceX Starship just nailed something it’s never done before

Nevertheless, more details are coming out about Starship, and Musk is doing the talking.

Starship Will Be Retrieved in the Ocean

Musk revealed on Tuesday night that Starship would be recovered by a ship in the Indian Ocean. SpaceX routinely tries to recover Starship after splashdown in an effort to find out more about the flight by examining the spacecraft afterward.

This helps engineers find out more about why things might have happened, allows them to examine any potential damage or anomalies that might have occurred, and increases the chances of an even more successful flight next time thanks to the additional information recovered.

Ship Could Have Been Caught by Tower Arms, Musk claims

Musk has already indicated that SpaceX will plan to attempt a catch of Starship with the 14th test flight. While this would be a major accomplishment, it would be an expected next step, considering the fact that the Super Heavy Booster has already been caught by the chopsticks on numerous occasions.

A ship catch would be a great indication of where SpaceX stands in terms of reusability and launch cadence. A successful catch with relatively no incidents would be a good sign that SpaceX is nearing a more frequent launch of Starship, but also that the reusability of the massive rocket would be something many would expect in the near future.

It is a necessity to make life multiplanetary.

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Elon Musk

Elon Musk updates the SpaceX timeline for Mars

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Rendering of a colonized Mars by way of SpaceX
Rendering of a colonized Mars by way of SpaceX

Elon Musk has updated his timeline for when humans will walk on Mars and for when ships will simply get there.

The objective of getting to Mars has been one of Musk’s biggest goals since becoming a serial entrepreneur and realizing that time on Earth is limited. Musk has said several times he hopes to die on Mars, and not by impact.

Musk now believes that people will be on Mars in “roughly 5 to 7 years.” He said that a Mars lander will get there “a few years sooner.”

The response from Musk comes after NASA Administrator Jared Isaacman said that SpaceX’s biggest priority is the Moon and not Mars. Because of this, Isaacman conceded that he believes nuclear power and propulsion investments will provide “potentially the pathway with the fewest miracles required to put four people on Mars in the next 10 to 15 years.”

Of course, this is what NASA can do through taxpayer funding and nuclear investments, he added.

Musk’s grand ambitions are much more optimistic than most, and it is certainly a double-edged sword. This is not the first time timelines for Mars have been somewhat lofty, especially to those normal thinkers like you and me, not super geniuses like Musk.

SpaceX Board has set a Mars bonus for Elon Musk

In fact, the SpaceX and Tesla frontman has said on at least a dozen occasions that we could be on Mars in the coming years. Musk said 2020 would be the big year as early as 2009. In 2020, he was “highly confident” of a landing in 2026, and had even said 2024 in a best-case scenario.

The point is, the range has varied, and it’s anyone’s guess when we’ll get there. This latest adjustment to the timeline is typical of Musk, and while the Moon has seemingly taken priority over Mars, it is still worth mentioning that the ultimate goal is to make life multiplanetary, and it starts potentially with the Red Planet.

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Investor's Corner

SpaceX gets an absolutely crazy price target after rough IPO

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Credit: SpaceX

SpaceX (NASDAQ: SPCX) got an absolutely crazy price target rating from Raymond James after the company experienced a tough first few weeks following its Initial Public Offering (IPO).

Despite the tumultuous start, SpaceX has plenty of believers, and the company’s massively successful Starship launch last Friday, its 13th test flight of the massive rocket, went so smoothly that Raymond James analysts pushed its price target on the company to roughly 7 times its current trading level.

SpaceX Starship just nailed something it’s never done before

The firm officially put a “Strong Buy” rating and an $800 price target on the stock. It currently trades at around $113. Its all-time high is $225.64, reaching this trading level shortly after shares first went public.

Raymond James’ price target is tied to the firm’s confidence after Starship’s 13th test flight. Analysts at the firm said it was an incremental step that reduces engineering risks, citing the widely successful heat shield test that CEO Elon Musk recently detailed, the smooth deployment of Starlink V3 satellites, and a successful in-space engine relight.

SpaceX also managed to see Starship splash down safely in the Indian Ocean, while the Super Heavy Booster fell down to the Gulf of America with no incidents.

It is interesting to see these launches have such a tremendous impact on the stock and what investors think of it. After SpaceX initially delayed the Starship launch last week, shares fell tremendously. Most probably did not realize that the stand-down is a standard practice, especially if everything is not perfect.

The mission was initially aborted due to an issue with Raptor engines. This was resolved, and Starship launched last Friday after another delay on Thursday, which was caused by weather.

Now that analysts have seen what SpaceX launches are capable of and how impressive the feat is, firms are adjusting their price targets accordingly, making it known that they have high expectations for the space exploration company.

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