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SpaceX’s first Starship engine suffers “expected” damage during Raptor test fire

Sometimes you have to crack a few Raptor eggs to make a Starship omelette. (SpaceX)

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SpaceX CEO Elon Musk says that the first full-scale Starship engine to be tested has already been pushed to the point of damage less than three weeks after the campaign began, setting the stage for the second full-scale Raptor to take over in the near future.

According to Musk, while most of the damaged pathfinder Raptor’s components should still be easily reusable, the assembly of the second finalized engine is “almost done” and that Raptor will take over near-term testing rather than waiting for repairs to the first engine. This is undoubtedly an extraordinarily aggressive test program, particularly for such a new and cutting-edge rocket propulsion system, but these latest developments are ultimately far more encouraging than they are concerning.

Although the Raptor engine family began integrated subscale static fires way back in September 2016, SpaceX’s propulsion team finalized Raptor’s baseline design and completed assembly, shipment, and an integrated static fire of the first full-scale engine on February 3rd, considerably less than three weeks before Musk took to Twitter. Aside from confirming that the new Raptor had been damaged during its most recent static fire several days prior, Musk indicated that the failure (unsurprisingly) was primarily attributed to the engine reaching the highest chamber pressures yet.

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Raptor’s main combustion chamber (the bit directly above the nozzle) has been designed to nominally operate at and reliably withstand extraordinary pressures of 250+ bar (3600+ psi), performance that demands even higher pressures in the components that feed hot methane and oxygen gas into Raptor’s combustion chamber. One prime example hinted at by Musk in a 2018 tweet is its oxygen preburner, used to convert liquid propellant into a high-velocity gas that can then feed a dedicated oxygen turbopump. Aside from the absurdly corrosive environment created by extremely hot gaseous oxygen, the preburner must also survive pressures that could peak as high as 800+ bar, or 12,000 psi.

 

A lack of technical detail means that it’s hard to know what thrust or main chamber pressure Musk had in mind when referring to exotic alloys that would be needed to survive those pressures, but the performance statistics of a Raptor with a preburner operating at 800+ bar would probably outstrip anything Musk has thus far described. In other words, it’s safe to assume that Raptor has probably not been pushed to those performance levels just yet, although it’s still a distant possibility. More likely is that 800+ bar in the oxygen preburner is an extreme stretch-goal that will take concerted research, development, and optimization to achieve, with Raptor having suffered damage somewhere below those levels while still reaching eye-watering performance figures.

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For an engine as complex as Raptor, there are countless dozens of potential failure modes the appearance of which would come as little surprise for an engine just days into full-scale testing. Above all else, the Raptor test schedule held by SpaceX’s world-class propulsion team – be it self-motivated or driven by reckless management-by-spreadsheet – has been fast-paced in the extreme, taking the first high-performance Raptor ever built from standstill to more than 90% thrust and chamber pressures of almost 270 bar (3900 psi) in – quite literally – less than one week. In the same period of time, more than half a dozen static fire tests (ranging from 1-10 seconds) were performed.

Within a few days of that February 10th milestone, in which Raptor reached chamber pressures comparable with the most advanced modern engines (namely RD-180/190/191), the engine was apparently pushed dramatically higher still, reaching a chamber pressure (and thus thrust) that wrought damage on some of the more sensitive parts of the engine’s plumbing. Despite the fact that the second production Raptor is apparently already “almost done”, Musk suggested that it would already feature changes (of unknown gravity) to mitigate the failure modes experienced by Raptor SN01.

In an industry where NASA and contractors like Aerojet-Rocketdyne will spend months between static fire tests of Space Shuttle engines that have each literally flown multiple (if not) dozens of missions to orbit and have a demonstrated performance and reliability record that is measured in the hundreds of thousands of seconds, the speed and agility of SpaceX’s Raptor development and test program is breathtaking. What remains to be seen is just how comparably reliable and successful the end results (i.e. operational Raptor) will be, but an attitude that actively accepts and even pursues testing to destruction can ultimately only serve to benefit the finished product at the cost of destroyed hardware and many on-ground lessons learned the hard ways.

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Given the immense success of SpaceX’s Merlin family of engines and the aggressive strategy of development and continuous improvement that brought it from Merlin 1A to 1D and MVacD, SpaceX is clearly not fumbling around in the dark when it comes to Raptor R&D.


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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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SpaceX set to launch Axiom’s mission for diabetes research on the ISS

Axiom’s Ax-4 will test CGMs & insulin stability in microgravity—potentially reshaping diabetes care for Earth & future astronauts.

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(Credit: SpaceX)

Axiom Space’s Ax-4 mission is set to launch on a SpaceX Falcon 9 rocket. Ax-4 will advance diabetes research in microgravity, marking a milestone for astronaut health.

Axiom Space’s fourth crewed mission is scheduled to launch with SpaceX on May 29 from NASA’s Kennedy Space Center in Florida. The Ax-4 mission will carry a diverse crew and a record-breaking scientific payload to the International Space Station (ISS).

The Ax-4 crew is led by Axiom’s Peggy Whitson and includes Shubhanshu Shukla from India, Sławosz Uznański from the European Space Agency, and Tibor Kapu from Hungary. The mission represents firsts for India, Hungary, and Poland, with Uznański being Poland’s first astronaut in over 40 years.

Ax-4 will conduct nearly 60 science investigations from 31 countries during its two-week ISS stay. A key focus is the “Suite Ride” initiative, a collaboration with Burjeel Holdings to study diabetes management in microgravity.

“The effort marks a significant milestone in the long-term goal of supporting future astronauts with insulin-dependent diabetes (IDDM), a condition historically deemed disqualifying for spaceflight,” Axiom noted. The mission will test Continuous Glucose Monitors (CGMs) and insulin stability to assess their performance in space.

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Axiom explained that testing the behavior of CGMs and insulin delivery technologies in microgravity and observing circadian rhythm disruption could help diabetes experts understand how CGMs and insulin pens can improve diabetes monitoring and care in remote or underserved areas on Earth. The research could benefit diabetes management in isolated regions like oil rigs or rural areas.

The mission’s findings on insulin exposure and CGM performance could pave the way for astronauts with diabetes to safely participate in spaceflight. As Axiom and SpaceX push boundaries, Ax-4’s diabetes research underscores the potential for space-based innovations to transform healthcare on Earth and beyond.

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EU considers SES to augment Starlink services

The EU considers funding SES to support Starlink. With MEO satellites already serving NATO, SES could be key in Europe’s space autonomy push.

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(Credit: SES)

European satellite company SES is negotiating with the European Union (EU) and other governments to complement SpaceX’s Starlink, as Europe seeks home-grown space-based communication solutions. The talks aim to bolster regional resilience amid growing concerns over reliance on foreign providers.

In March, the European Commission contacted SES and France’s Eutelsat to assess their potential role if American-based Starlink access for Ukraine was disrupted. The European Commission proposed funding EU-based satellite operators to support Kyiv. Ukraine is considering alternatives to Starlink over concerns about Elon Musk’s reliability.

Arthur De Liedekerke of Rasmussen Global warned, “Elon Musk is, in fact, the guardian of Ukraine’s connectivity on the battlefield. And that’s a strategic vulnerability.” However, SpaceX’s Starlink constellation is leagues ahead of any competition in the EU.

“Now the discussions are much more strategic in nature. They’re much more mid-term, long-term. And what we’re seeing is all of the European governments are serious about increasing their defense spending. There are alternatives, not to completely replace Starlink, that’s not possible, but to augment and complement Starlink,” SES CEO Adel Al-Saleh told Reuters.

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SES operates about 70 satellites, including over 20 medium Earth orbit (MEO) units at 8,000 km. The company provides high-speed internet for government, military, and underserved areas. It plans to expand its MEO fleet to 100, enhancing secure communications for NATO and the Pentagon.

“The most significant demand (for us) is European nations investing in space, much more than what they did before,” Al-Saleh said.

Competition from Starlink, Amazon’s Kuiper, and China’s SpaceSail, with their extensive low-Earth orbit constellations, underscores Europe’s push for independence.

“It is not right to say they just want to avoid Starlink or the Chinese. They want to avoid being dependent on one or two providers. They want to have flexibility,” Al-Saleh noted.

SES’s discussions reflect Europe’s strategic shift toward diversified satellite networks, balancing reliance on Starlink with regional capabilities. As governments ramp up defense spending, SES aims to play a pivotal role in complementing global providers, ensuring robust connectivity for military and civilian needs across the continent.

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Amazon launches Kuiper satellites; Can it rival Starlink?

With 27 satellites in orbit, Amazon kicks off its $10B plan to deliver global broadband. Can Bezos’ Kuiper take on Musk’s Starlink?

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(Credit: Amazon)

Amazon’s Project Kuiper launched its first 27 satellites on Monday, marking the start of a $10 billion effort that could compete with SpaceX’s Starlink with a global broadband internet network.

Amazon’s Kuiper satellites launched aboard a United Launch Alliance Atlas V rocket from Cape Canaveral, Florida. Project Kuiper’s recent launch is the initial step toward deploying Amazon’s 3,236 satellites for low-Earth orbit connectivity. Amazon’s satellite launch was initially set for April 9 but was delayed due to bad weather.  

Now that the Kuiper satellites have been launched, Amazon is expected to publicly confirm contact with the satellites from its mission operations center in Redmond, Washington. The company aims to start offering Kuiper services to customers later this year. Project Kuiper was unveiled in 2019 and targets consumers, businesses, and governments who need reliable internet service, similar to Starlink.

Amazon has a deadline from the U.S. Federal Communications Commission to deploy 1,618 satellites by mid-2026. Analysts suggest the company may require an extension to its Kuiper satellite deployment deadline due to the project’s year-long delay from its planned 2024 start.

United Launch Alliance could conduct up to five more Kuiper missions this year, according to ULA CEO Tory Bruno. Amazon noted in a 2020 FCC filing that Kuiper services could begin with 578 satellites, initially covering northern and southern regions.

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Kuiper’s launch pits Amazon against SpaceX’s Starlink and telecom giants like AT&T and T-Mobile, with a focus on underserved rural areas.

“There’s an insatiable demand for the internet,” Amazon Executive Chairman Jeff Bezos told Reuters in January. “There’s room for lots of winners there. I predict Starlink will continue to be successful, and I predict Kuiper will be successful as well.”

Global interest in satellite alternatives is rising. Ukraine is exploring Starlink alternatives with the European Union (EU), driven by concerns over Elon Musk. Germany’s military, Bundeswehr, also plans its own constellation to ensure independent communications. However, like Amazon’s Kuiper Project, EU options lag behind Starlink.

Amazon’s consumer expertise and cloud computing infrastructure give Kuiper a competitive edge despite Starlink’s market lead. As Kuiper ramps up launches, its success could reshape broadband access while challenging SpaceX’s dominance in the satellite internet race.

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