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

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3 years ago

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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.

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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.

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.

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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

Countdown: America is going back to the Moon and SpaceX holds the key to what comes after

NASA’s Artemis II launches Wednesday, sending humans near the Moon for the first time since 1972.

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2 hours ago

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March 31, 2026

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For the first time since Apollo 17 touched down on the lunar surface in December 1972, the United States is sending humans back toward the Moon. NASA’s Artemis II mission is set to launch as early as this week from Kennedy Space Center in Florida, carrying four astronauts on a 10-day journey around the Moon and back to Earth. It will not land anyone on the surface this time, but it is the first crewed flight in over half a century to travel beyond low Earth orbit, and it sets the stage for Elon Musk’s SpaceX missions to follow.

The mission uses NASA’s Space Launch System rocket and the Orion spacecraft, which will fly around the Moon before splashing down in the Pacific Ocean around April 10. For context, an uncrewed Artemis I flew the same path in 2022, proving the hardware worked. Artemis II now tests it with people aboard.

According to NASA’s official countdown blog, launch preparations are on track with an 80 percent chance of favorable weather. “Hey, let’s go to the moon!” Commander Wiseman told reporters upon arriving at Kennedy Space Center.

Source: NASA

Beyond Artemis II lies the lander question, and that is where SpaceX enters directly. In 2021, NASA awarded SpaceX a $2.89 billion contract to develop the Starship Human Landing System, a modified version of Starship designed to ferry astronauts from lunar orbit to the surface. The original plan called for SpaceX to deliver that lander for Artemis III, which was to be the first crewed lunar landing. Timing for Starship development, however, caused NASA to restructure the mission sequence entirely.

Before SpaceX’s Starship Human Landing System (HLS) can put anyone on the Moon, it has to solve a problem no rocket has demonstrated at scale, which is refueling in orbit. Because the Starship HLS requires approximately ten tanker launches worth of propellant loaded into a depot in low Earth orbit before it has enough fuel to reach the lunar surface, SpaceX plans to conduct this refueling process using its upgraded V3 Starship. And until that demonstration flies and succeeds, the Starship moon lander remains a question mark.

SpaceX’s Starship V3 is almost ready and it will change space travel forever

In February 2026, NASA Administrator Jared Isaacman confirmed that Artemis III, now planned for mid-2027, and will instead test lunar landers in low Earth orbit, with the actual landing pushed to Artemis IV that’s targeted for 2028.

Musk responded to earlier criticism of SpaceX’s schedule by posting on X that his company is “moving like lightning compared to the rest of the space industry,” and added that “Starship will end up doing the whole Moon mission.” The contract competition was also reopened in October 2025 by then NASA chief Sean Duffy, who cited Starship’s delays and said the agency needed speed given China’s own stated goal of landing astronauts on the Moon by 2030.


Artemis came from the first Trump administration’s 2017 Space Policy Directive 1, which directed NASA to return humans to the Moon. The program picked up pace through the 2020s, with the Orion spacecraft and SLS taking years to develop at enormous costs. SpaceX entered the picture in 2021 as the chosen lander contractor, tying the commercial space sector into what had historically been an all government undertaking.

Whether SpaceX’s Starship ultimately carries astronauts to the lunar surface or shares that role with Blue Origin’s competing lander, this week’s Artemis II launch is the necessary first step. Getting four humans to the Moon’s vicinity and back safely is the proof of concept everything else depends on.

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Elon Musk

Elon Musk debunks latest rumors about SpaceX IPO

Musk has swiftly put to rest circulating reports suggesting that SpaceX would exclude popular retail brokerages Robinhood and SoFi from its highly anticipated initial public offering. In a direct response posted on X on March 31, Musk stated simply, “These reports are false,” addressing widespread speculation fueled by a Reuters article.

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3 hours ago

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March 31, 2026

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(Credit: SpaceX)

Tesla and SpaceX CEO Elon Musk debunked the latest rumors about the space exploration company’s initial public offering (IPO), which has been the subject of a wide array of speculation over the last few weeks.

With SpaceX likely heading to Wall Street to become a publicly-traded stock in the coming months, there is a lot of speculation surrounding how it will happen, whether the company will potentially combine with Tesla, and more.

Tesla and SpaceX to merge in 2027, Wall Street analyst predicts

But the latest rumors have to do with where SpaceX will list the stock.

Musk has swiftly put to rest circulating reports suggesting that SpaceX would exclude popular retail brokerages Robinhood and SoFi from its highly anticipated initial public offering.

In a direct response posted on X on March 31, Musk stated simply, “These reports are false,” addressing widespread speculation fueled by a Reuters article.

The Reuters report, published March 30, claimed that Morgan Stanley’s E*Trade was in talks to lead the sale of SpaceX shares to small U.S. investors.

Sources indicated that Robinhood and SoFi, despite pitching for roles, faced potential exclusion from the retail allocation, with Fidelity also competing for a piece of the action. The story quickly spread across financial media, raising concerns among retail investors eager to participate in what could be one of the largest IPOs in history.

SpaceX has a reported valuation nearing $1.75 trillion, and Musk’s plan to allocate up to 30 percent of shares to individual investors — far above the typical 5-10% — had generated massive excitement.

Musk’s concise denial immediately calmed the narrative. The original X post quoting the rumor garnered significant engagement, with users expressing relief that everyday investors would not be sidelined.

This episode reflects Musk’s hands-on approach to SpaceX’s public debut.

Earlier reporting revealed plans for an unusually large retail slice to leverage Musk’s dedicated fan base and stabilize post-IPO trading. SpaceX aims to file potentially as early as this period, building on momentum from its Starship program and Starlink growth.

The IPO could mark a transformative moment, potentially elevating Musk’s status further while democratizing access to a company long reserved for accredited investors and institutions.

The rumor’s quick debunking also revives debates about retail access in high-profile listings. Robinhood gained popularity during the 2021 meme-stock surge but faced criticism for past trading restrictions.

SoFi has positioned itself as a modern financial platform for younger investors. Excluding them could have limited participation from tech-savvy retail traders who form a core part of Musk’s supporter base across Tesla and SpaceX.

While details remain fluid, Musk’s intervention reinforces commitment to broad accessibility. As preparations advance, investors await official filings. For now, the message is clear: rumors of restricted retail access were overstated, keeping the door open for widespread participation in SpaceX’s public chapter.

This development comes amid broader market enthusiasm for space and technology stocks. Musk’s transparency through X continues to shape public perception, distinguishing SpaceX’s path from traditional Wall Street norms. With retail allocation potentially reaching 30 percent, the IPO promises to be both commercially massive and culturally significant.

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Elon Musk

Tesla Optimus Gen 3 is coming to the Tesla Diner with new ambitions

Tesla’s Optimus robot left the Hollywood Diner within months of opening. Now Musk is planning its return with a bigger role and a major Gen 3 upgrade underway.

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20 hours ago

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March 30, 2026

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla’s Optimus robot was one of the most talked-about features when the Tesla Diner opened on Santa Monica Boulevard in Hollywood on July 21, 2025. Dubbed “Poptimus” by Tesla fans, the Gen 2 robot stood upstairs at the retro-futuristic, drive-in theater and Tesla Supercharging station, scooping popcorn into bags and handing them to guests with a wave.

The diner itself had been years in the making. Elon Musk first floated the idea in 2018 with a tweet about building an “old-school drive-in, roller skates & rock restaurant” at a Hollywood Supercharger. What eventually opened was a unique two-story neon-lit space, with 80 EV charging stalls, and Optimus serving as a live demonstration of where Tesla’s ambitions were headed.


But Optimus did not stay long, and was gone by December 2025.

Now, the robot is set to return with a more demanding job. Musk has ambitions for Optimus to take on a food runner role in 2026, delivering meals directly to cars at the Supercharger stalls. While the latest Gen 3 Optimus is likely to initially take on its previous popcorn-serving role, it wouldn’t be out of the question for Optimus to see a quick promotion. With improved  hand dexterity that features 50 total actuators and 22 degrees of freedom per hand, and significantly more powerful processing through Tesla’s latest AI5 chip that includes Grok-powered voice interaction, Musk described Optimus at the Abundance Summit on March 12, 2026, as “by far the most advanced robot in the world, Nothing’s even close.”

That confidence is backed by a major manufacturing shift. At the Q4 2025 earnings call in January, Musk announced Tesla would discontinue the Model S and Model X and convert those Fremont production lines to build Optimus. “It’s time to basically bring the Model S and X programs to an end,” he said, calling for a pivot that reflects where the Tesla’s future lies.

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