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SpaceX, ULA win multibillion-dollar military launch contract years in the making

SpaceX is now set to create an upgraded Falcon fairing and build a massive, mobile building to satisfy stringent US military requirements. (SpaceX)

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Ending a process that began almost two years ago, the US Air Force (now Space Force) has selected SpaceX and ULA to be the recipients of a multibillion-dollar series of launch contracts that stretch into the late 2020s.

Known as the National Security Space Launch Phase 2 Launch Services Acquisition (LSA), the US Air Force publicly began the initiative in Q4 2018. In May 2019, the LSA process was opened to bidders and the military ultimately received serious proposals from SpaceX, the United Launch Alliance (ULA), Northrop Grumman, and Blue Origin.

While the latter three companies proposed their respective next-generation rockets – still in development – to complete at least a dozen military launches from 2022 to 2027, SpaceX offered up Falcon 9 and Falcon Heavy. As of April 2020, Falcon 9 officially usurped ULA’s Atlas V rocket to become the United States’ most prolific operational rocket. While ULA has technically included Atlas V as a backup option in its NSSL Phase 2 bid, the company’s primary launch vehicle is Vulcan Centaur, scheduled to fly for the first time no earlier than July 2021.

(Teslarati – ULA/NGIS/Blue Origin/SpaceX)

As a result, failing to award SpaceX at least one of the two NSSL LSA Phase 2 slots – split 60:40 – would have almost assuredly made a farce of the US military competition. The real question, then, was who would win the other award, and whether the US military would shock the industry with a final decision more technical than political. As previously discussed on Teslarati, the fact that four separate companies submitted serious bids for Phase 2 gave the US military a significant opportunity.

“For dubious reasons, the US Air Force (USAF) has structured the NSSL Phase 2 acquisition in such a way that – despite there being four possible competitors – only two will be awarded contracts at its conclusion. The roughly ~34 launch contracts up for grabs would be split 60:40 between the two victors, leaving two competitors completely empty handed.”

Teslarati.com — August 14th, 2019

Despite repeated petitions by Blue Origin and the attempted intervention of lawmakers in Congress, the US military remained ardently against awarding Phase 2 launch contracts to more than two providers throughout the competition. Barring a successful protest from snubbed bidders Northrop Grumman and/or Blue Origin, it appears that the military ultimately won the battle, selecting two providers.

Omega. (Northrop Grumman)
New Glenn. (Blue Origin)

Instead of awarding even just a handful of the 34 launch contracts up for grabs to Northrop Grumman, the US Space Force is all but guaranteeing that the company’s Omega rocket will die in the cradle without an immediate slew of additional military contracts. There’s a chance that NSSL Phase 1 LSA funding will continue, likely giving NG the money it needs to complete Omega’s development, but that’s far from guaranteed.

Funded entirely out of Jeff Bezos’ pocket, Blue Origin’s ambitious New Glenn reusable rocket is more insulated from a lack of US military contracts and the company could also continue to receive several hundred million dollars as part of an LSA Phase 1 award. For Blue Origin, already set on entering New Glenn into the commercial launch market, military funding could ensure that the company does the extra work needed to certify the rocket and its production facilities for military launches.

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Down the road, that means that the US Air Force, Space Force, or National Reconnaissance Office (NRO) could all feasibly award Blue Origin or Northrop Grumman launch contracts outside the 34 Phase 2 missions without having to start a development and certification process that can take a year or more from scratch.

SpaceX completed its first operational US military Falcon 9 launch on June 30th. (Richard Angle)

Regardless of the missed opportunities, the NSSL LSA Phase 2 contract is a major win for SpaceX and guarantees the company’s Falcon 9 and Falcon Heavy rockets some 13-14 military launch contracts over a five-year period. For ULA, the victory is likely a massive relief, given that the company’s next-generation (expendable) Vulcan Centaur rocket has next to no chance of sustaining itself with commercial launch contracts. Much like Atlas V in the last decade of the rocket’s life and Delta IV over most of its two-decade career, ULA’s Vulcan rocket will continue the trend of relying almost exclusively on US military contracts.

This time around, however, the US military’s preferential treatment of ULA is nakedly obvious. At almost every turn, SpaceX’s Falcon 9 and Falcon Heavy rockets can provide the same launch services as ULA for anywhere from 20-50% less. For the few missions (direct to geostationary) where ULA’s Atlas V, Delta IV, and Vulcan rockets might actually have a step up over SpaceX, the US could have easily awarded ULA the smaller 40% share or even split that 40% share with Blue Origin or Northrop Grumman, giving SpaceX the lion’s share and likely saving hundreds of millions of dollars – if not $1B+ – over the next seven years.

Instead, business (more or less) as usual will continue for at least another decade as the US military functionally subsidizes ULA’s existence by prioritizing a more expensive rocket to achieve the same outcome. The first LSA Phase 2 launches are currently scheduled to begin no earlier than (NET) 2022.

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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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Tesla eyes supply partners for Optimus mass production

Tesla certified three Chinese suppliers for Optimus mass production, signaling its robot timeline is accelerating.

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Concept rendering of Tesla Optimus in mass production

Tesla’s robotics team traveled to Ningbo, in China’s Zhejiang province, on September 16 and spent the following day auditing component suppliers for Optimus, according to a Bloomberg report cited by RobotAIGeek. The visit moved three manufacturers from provisional status to certified mass production partners: Tuopu Group, which handles actuators and chassis components, Ningbo Joyson Electronic, a sensor supplier, and Zhejiang Sanhua Intelligent Controls, which builds thermal management systems. All three already supply parts to Tesla’s electric vehicles, and the audit reportedly came with fresh orders that supply chain reports put at an initial batch of roughly 5,000 units.

Tuopu, Joyson, and Sanhua built their manufacturing base serving the automotive industry, where tolerances and volume requirements are already close to what a mass produced humanoid robot demands. Sanhua in particular has history here. Teslarati reported last October that the company had received a roughly $685 million order for linear actuators tied to Optimus, a volume industry watchers estimated could cover around 180,000 robots once production ramped.

Supply chain reports tied to this week’s audit put Tesla’s near term production goal at about 1,000 Optimus units a week by late September, rising to 2,000 to 2,500 units a week by the end of the year. That pace would put real weight behind the timeline Tesla has been building toward since May, when it wound down Model S and Model X production at Fremont to convert that floor space into a dedicated Optimus line targeting one million units annually. JPMorgan analysts who toured the factory in August confirmed the conversion took roughly four months, a pace Musk has called unprecedented for a facility that size.

New drone video shows Tesla’s Optimus Factory reaching a turning point

Fremont is only the first phase. A second, larger Optimus plant is rising at Gigafactory Texas, where drone footage shared by Joe Tegtmeyer last week showed the structural steel nearing completion on the north end of the building. Tesla has said that facility is meant to eventually support production of up to 10 million units a year, though volume output there is not expected before 2027.

Commercial sales of Optimus are still targeted for the second half of 2027, but production is expected to start well before then. JPMorgan analyst Rajat Gupta has said Tesla’s “Optimus Academy” program, which uses early units to collect real world training data inside Tesla’s own facilities, is expected to be running later this year. Bloomberg Intelligence analyst Ian Ma described the Ningbo audits as “a positive commercialization signal for China’s humanoid supply chain,” noting that sentiment could improve further if the visit leads to confirmed supplier nominations and larger orders. The Solactive China Humanoid Robotics Index rose about 1.4% on the news, though it remains down roughly 30% for the year.

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Elon Musk’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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