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SpaceX calls ULA NASA launch contract “vastly” overpriced in official protest

Falcon 9 B1054 lifts off on SpaceX's first expendable Block 5 launch. (SpaceX)

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7 years ago

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SpaceX has filed an official protest with the US Government Accountability Office (GAO) after NASA awarded competitor United Launch Alliance a launch contract for Lucy, an interplanetary probe meant to explore a belt of unique asteroids clustered around Jupiter’s orbital swath.

Announced on January 31st, SpaceX believes that NASA made a decision counter to the best interests of the agency and US taxpayers by rewarding ULA the Lucy launch contract at a cost of $148M, a price that the company deemed “vastly more [expensive]” than the bid it submitted for the competition.

With performance roughly equivalent to SpaceX’s Falcon 9 Block 5 rocket in a reusable configuration when launching from low Earth orbit (LEO) up to geostationary transfer orbit (GTO), ULA’s Atlas V 401 variant is the simplest version of the rocket family with the lowest relative performance, featuring no solid rocket boosters. According to the company’s “RocketBuilder” tool, Atlas V 401 was listed with a base price of $109M in 2017. SpaceX’s Falcon 9 is listed with a base price of $62M for a mission with booster recovery, while the rocket’s highest-value expendable launch (for a USAF GPS III satellite worth ~$530 million) was awarded at a cost of $83M, with three subsequent GPS III launch contracts later awarded for ~$97M apiece.

Relative to almost any conceivable near-term launch contract on the horizon, SpaceX’s GPS III launch contracts act as a sort of worst-case price tag for Falcon 9, where the customer requires extraordinary mission assurance and the entire rocket has to be expended during the launch. Put in another way, NASA would likely be able to get the reliability, performance, and mission assurance it wants/needs from Falcon 9 for perhaps $50M less than the cost of ULA’s proposed launch, equivalent to cutting more than a third off the price tag. Part of NASA’s Discovery Program, the Lucy spacecraft will be capped at $450M excluding launch costs, meaning that choosing SpaceX over ULA could singlehandedly cut the mission’s total cost by a minimum of 8-10%.

 

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“Since SpaceX has started launching missions for NASA, this is the first time the company has challenged one of the agency’s award decisions. SpaceX offered a solution with extraordinarily high confidence of mission success at a price dramatically lower than the award amount, so we believe the decision to pay vastly more to Boeing and Lockheed for the same mission was therefore not in the best interest of the agency or the American taxpayers.”  – SpaceX, February 13th, 2019

The fact remains that the Lucy mission does face a uniquely challenging launch trajectory, offering just a single launch window of roughly three weeks, after which the mission as designed effectively becomes impossible. Missing that window could thus end up costing NASA hundreds of millions of dollars in rework and delays, if not triggering the mission’s outright cancellation. NASA and ULA thus couched the launch contract award and ~50% premium in terms of what ULA argues is Atlas V’s “world-leading schedule certainty”. Excluding ULA’s other rocket, Delta IV, Atlas V does have a respectable track record of staying true to its contracted launch targets. However, SpaceX’s Falcon 9 “schedule certainty” continues to improve as the launch vehicle matures.

Admittedly, while Falcon 9 has gotten far better at reliably launching within 5-10 days of its on-pad static fire test, SpaceX has continued to struggle to launch payloads within a week or two of customer targets. Regardless, October 2021 is more than two and a half years away, giving SpaceX an inordinate amount of time and dozens upon dozens of manifested Falcon 9 launches to reach a level of operational maturity and design stability comparable to Atlas V, a rocket that has changed minimally over the course of 16+ years and 79 launches.

 

In October 2010, NASA awarded ULA a contract valued at $187M to launch its MAVEN Mars orbiter on Atlas V 401. In December 2013, ULA won a $163M contract to launch NASA’s InSight Mars lander on Atlas V 401. In January 2019, ULA was awarded a contract for NASA’s Lucy spacecraft, priced at $148.3M for a 2021 Atlas V 401 launch. Put simply, barring ULA using a dartboard and blindfold to determine launch contract pricing or aggressive reverse-inflation, SpaceX’s very existence already stokes the flames of competition, particularly when launch contracts are directly competed by their parent agencies or companies.

Whether or not SpaceX’s protest is entirely warranted or ends up amounting to anything, it can be guaranteed that the fact that SpaceX was there to compete with ULA at all forced the company to slash anywhere from $20-40M from the price it would have otherwise gladly charged NASA. Another ~$50M saved would certainly not be the worst thing to happen to the US taxpayer, but it’s also not the end of the world.

Check out Teslarati’s newsletters for prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket launch and recovery processes!

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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

Tesla’s mysterious Robovan makes a sneak peek with Optimus in Terafab video

Elon Musk shared a new Terafab video showing Optimus, Robovans, and a stunningly futuristic campus.

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13 hours ago

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August 6, 2026

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SpaceX Terafab rendering

Elon Musk posted a new video of Terafab on X Thursday morning, and the most eye-catching details in it were not the building itself, but two products still awaiting production: Optimus and the Robovan.

The concept render, credited to SpaceX, shows Optimus robots working the grounds of the roughly 2.5-mile-long facility planned for the Gibbons Creek site in Grimes County, while a Robovan glides along an elevated roadway cutting through the building itself, sharing the frame with a Tesla Semi and a Cybercab.

Robovan is the boxy, driverless people and cargo mover Musk unveiled alongside Cybercab at Tesla’s “We, Robot” event in October 2024. He pitched it as a way to move up to 20 passengers at once, or handle freight instead, at a target cost he claimed could fall under a dollar a mile, with no steering wheel or pedals, the same layout as Cybercab. Nearly two years later, Robovan still has no confirmed production timeline and has not shown up in any factory footage, which makes Thursday’s render one of the only recent looks at the vehicle in any form.

Optimus has moved further along. Tesla began converting Fremont’s old Model S and Model X assembly line into a Gen 3 Optimus production line earlier this year, and Musk visited the site on July 1 to mark the changeover. A second, larger Optimus plant is under construction at Giga Texas, targeting volume production in summer 2027 and eventual capacity of 10 million units a year. Tesla AI lead Ashok Elluswamy said this month the robot has “big shoes to fill” in replacing the S and X line, while Musk has repeatedly called Optimus the company’s biggest product of any kind, with a long-term price he has pegged between $20,000 and $30,000.

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“Terafab Texas will be the largest and most valuable building on Earth by far,” Musk wrote alongside the clip. “And it will be stunningly beautiful.”

One quote post summed up the reaction: “Futuristic scene with RoboVan + Cybercab + Tesla Semi + Optimus.”

Beyond the vehicles, the architecture wrapped around them stands out too. The building’s facade is canted at sharp angles, with illuminated horizontal bands running through what appears to be a multi level interior visible from outside. Below the elevated roadway, pedestrians walk along a plaza next to a reflecting pool, and the skyline behind the campus is dotted with angular spires that read more like sculpture than infrastructure, a departure from the strictly utilitarian look of Gigafactory Texas or Starbase.

The timing tracks with what Terafab representative Riley Trennell told Grimes County residents on Wednesday, when he said renderings of the facility would be released “within days.” Musk’s post followed less than 24 hours later, and Texas Governor Greg Abbott’s office sent out its own release Thursday confirming the project. As Teslarati reported this morning, Terafab’s tax abatement agreements with Grimes County are now signed and active, and SpaceX has sent the county its first $10 million payment under that deal. The dollar figure tied to this phase of construction, per Reuters, is $16.8 billion, one of the first hard capital expenditure numbers attached to Terafab since Musk unveiled the joint Tesla-SpaceX-xAI venture in March.Reaction on X ranged from enthusiastic to skeptical. “God Bless Texas! Everything is bigger and better in Texas!” one reply read. Another was more measured: “Terafab in a decade…..”

Whether the finished building matches the render is a separate question from whether Musk wanted people talking about the render itself. Less than a day after posting, the video had already crossed 5.5 million views.

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Elon Musk

Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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1 day ago

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August 5, 2026

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

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SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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Elon Musk

SpaceX has solved Starship’s biggest challenge, Elon Musk says

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2 days ago

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August 5, 2026

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

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During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

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

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

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Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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