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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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Rivian grapples with challenges from Trump’s auto tariffs

Rivian CEO warns Trump’s auto tariffs will squeeze the EV industry. Scaringe says auto tariffs threaten rising costs & slower production.

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(Credit: Rivian)

Rivian is grappling with challenges arising from President Trump’s auto tariff. Rivian CEO RJ Scaringe recently enumerated the difficulties automakers face and elaborated on the impact of Trump’s auto tariffs on the electric vehicle (EV) industry.  

President Trump’s auto tariffs were announced last month, imposing 25% tariffs on imported vehicles effective April 3, 2025, and levies on auto parts starting in May.

Scaringe talked a bit about the complexity of the automotive supply chain with Fox Business. Rivian’s R1T pickup, R1S SUV, and commercial electric van are manufactured at its Normal, Illinois plant. Scaringe boasted that Rivian has a “very U.S.-centric supply chain.

Yet, the complex global supply chain poses hurdles for U.S. automakers who want to comply with Trump’s auto tariffs.

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“One of the things with automotive is the supply chain is so complex, where we have hundreds of suppliers providing parts from, say, a headlight or a tow hook or tires or the structure under the skin here that are coming from not only a set of suppliers that supply to us, but those suppliers have suppliers, and then in turn, those suppliers have suppliers, so there’s tier two, tier three,” Scaringe explained.

China’s restrictions on rare-earth material exports–in response to Trump’s 145% tariff on Chinese imports–further complicate matters. Rare-earth materials are critical for EV motor magnets and batteries. Nearly all rare-earth materials are processed exclusively in China.

“The trade restrictions and what we’re seeing in terms of rare earth metals out of China, that’s a real challenge for electric vehicles,” Scaringe noted.

Batteries comprise up to 40% of an EV’s cost. Goldman Sachs noted that battery costs have been falling in recent years. The investment bank estimated EV battery costs would drop by 50% between 2023 and 2026. However, China’s decision to restrict rare-earth materials may increase battery costs.

Wedbush analyst Dan Ives called the tariffs a source of “pure chaos” for the auto industry, stating, “A U.S. car made entirely with U.S. parts is a fictional tale.”

Ives warned automakers could increase car prices between $5,000 to $10,000. Wedbush predicts a potential change in Trump’s auto parts tariffs could ease disruptions.

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For Rivian, starting prices near $70,000 limit room for cost increases without impacting sales. As trade tensions escalate, Rivian faces rising costs and potential production slowdowns, threatening its growth in a shifting EV landscape.

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New Starlink router gets FCC approval, hints at dish upgrades

The new Starlink router hints at upcoming dish upgrades & faster service. SpaceX is setting the stage for 2 Gbps internet

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(Credit: Starlink)

SpaceX’s new Starlink router, model UTR-251, has secured FCC approval for U.S. sales. The new Starlink router hints at upcoming dish upgrades and improvements to SpaceX’s satellite internet service.

Starlink’s new router design and specs suggest ties to an updated high-performance dish or a new Starlink product. The UTR-251 succeeds the Gen 3 router (UTR-231 and UTR-232), launched in 2023.

Unlike its predecessor’s dual Ethernet ports, Starlink’s new router features a single port designed for “Indoor Use only,” with a vertical form resembling the Gen 2 router. FCC filings reveal WiFi 6 support and a higher “watt output” for expanded frequencies, including the 5.9GHz UNII-4 band, enhancing spectrum access.

Tim Belfall, a director at UK-based Starlink installer Westend WiFi, noted the router’s lower power needs. The new Starlink router needs a 9 Volt by 1.6 Amp, 14.4-watt input, compared to the Gen 3’s higher demands. The new router has significantly lower power requirements than the current Gen 3 router, suggesting compatibility with a smaller Starlink dish.

SpaceX is developing three new dish models, including a refreshed flat high-performance dish for enterprise users. Ukrainian engineer Oleg Kutkov noticed recent code changes in Starlink dishes, which he believes means SpaceX is ready to produce its high-performance dish.

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In a webinar last month, SpaceX teased a new Starlink dish promising gigabit internet speeds, far surpassing the current average. SpaceX President Gwynne Shotwell highlighted the upgrade in 2024, stating, “Next generation, we’ll have smaller beams, more capacity per beam, lower latency.” She projected speeds up to 2 gigabits with the next-gen dish, positioning Starlink as a leader in high-speed satellite internet.

The UTR-251’s approval marks a step toward SpaceX’s vision of enhanced connectivity, though its exact role remains unclear. As SpaceX refines its hardware, the router’s advanced specs and efficiency underscore its push for faster, more reliable internet.

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Swedish unions upset after Tesla opens two new Superchargers

Tesla seems to be getting better at overcoming the unions’ blockades.

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Credit: TeslaCharging/X

Tesla Sweden is still dealing with a number of strikes due to its conflict with IF Metall, but the electric vehicle maker seems to be getting better at overcoming the unions’ efforts. 

Tesla’s clever workarounds have resulted in network owner Telge Nät apologizing to the unions after two new Superchargers were opened despite the sympathy strikes of the Elektrikerna union and Seko.

Tesla Sweden’s New Superchargers

While Tesla’s main conflict in Sweden is with trade union IF Metall, a number of other unions have initiated sympathy strikes against the company. These include the Elektrikerna union and Seko, both of which have initiated efforts to block the launch of new Superchargers.

As noted in a CarUp report, however, Tesla Sweden recently opened two new Supercharger locations in the city of Södertälje. The first was a site with 16 Supercharger stalls in the Moraberg shopping area, and it was followed by a large 20-stall Supercharger at Vasa Handelsplats. The new Superchargers were appreciated by EV owners, as even non-Teslas use them, and they are among the most reliable and most affordable in the market.

Tesla Sweden celebrated the launch of its two new Superchargers in the country. “Södertälje is a long-awaited destination for fast charging, and Tesla’s two new stations enable comfortable, fossil-free, and economical trips between the east and west coasts and to southern Sweden,” the electric vehicle maker stated.

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Angry Unions and Apologies

The unions were not happy at all that Tesla Sweden was able to overcome their blockade. Dennys Bello, press officer for the Elektrikerna union, noted that Tesla seems to be tapping the services of foreign companies and flying in people to help launch its charging stations. “It is a good question how this has happened. We think it is unfortunate. But they seem to have their methods. They bring in foreign companies and fly in people, we think,” Bello stated.

Network owners Telge Nät has issued an apology to the unions, stating that they regret the launch of the new Superchargers. In a comment, Erik Elowsson, press officer at the Telge Group, highlighted that they are not in any way overriding the union’s efforts. 

“We can confirm that two Tesla-owned facilities in Södertälje have been connected contrary to the purpose of the current conflict measures. We regret this. We want to make it clear that we had no intention of overriding Seko’s conflict measures. We have taken strong measures to ensure that this does not happen again. We respect the Swedish model, and stand up for the value of collective agreements and see strength in the dialogue we have with Seko,” Elowsson stated.

Seko, for their part, demanded an apology and correction from Telge Nät. As per Seko’s head of information Jonas Pettersson, “The company has responded that it is a mistake, and we have had a good dialogue with them. They have said that this will never be repeated. Of course, it is unfortunate that it has happened. We feel confident that Telge is now taking the necessary measures to ensure that it never happens again.”

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