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What’s causing SpaceX’s Falcon Heavy delays?

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Although uncertainty in the schedule remains, SpaceX’s Falcon Heavy rocket appears to be nearly ready for its first engine ignition test (called a ‘static fire’) sometime within the next week or so.

An attempt at 1 PM EST today, January 16, was canceled for unspecified reasons, although Kennedy Space Center reportedly maintained the usual roadblock to prevent vehicles from driving past, implying that SpaceX still intends to conduct propellant loading tests with Falcon Heavy. It was noted earlier this morning by spaceflight journalist Chris Bergin that things were “a bit too quiet” if a test was indeed planned for today, and his intuition appears to have been correct. It still remains the case that Falcon Heavy is an experimental and untested rocket to an extent, and these delays are to be expected as SpaceX works out the inevitable kinks and bugs that arise during the extensive testing big launch vehicle has been and is still being put through.

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Due to range requirements in support of an upcoming launch of the United Launch Alliance’s (ULA) Atlas 5 rocket, currently NET Thursday, SpaceX has postponed the static fire of Falcon Heavy without a replacement date. It is unlikely that another attempt will occur before the upcoming weekend, but SpaceX should have at least a solid week of uninterrupted range support once ULA’s launch occurs, hopefully without delay. Godspeed to ULA, in the meantime.

The crazy complexity of rocketry

Most recently, and perhaps somewhat related to Falcon Heavy’s static fire delays, SpaceX completed as many as two complete wet dress rehearsals (WDRs), which saw Falcon Heavy topped off with full tanks of its cryogenic (super cool) liquid oxygen (LOX) and rocket-grade jet fuel (RP-1). In essence, the rocket became equivalent to several hundred tons of carefully stabilized explosive. Nominally, these rehearsals appear entirely uneventful to an outside observer, with little more than ice formation and the occasional bursts of propellant tank vents to suggest that something important is occurring. However, anomalies like the failure of Falcon 9 during the Amos-6 static fire provide a staggering demonstration of just how explosive and sensitive a rocket’s fuel is, and Falcon Heavy has approximately three times the fuel capacity of Falcon 9. Empty, Falcon 9’s mass has been estimated to be around 30 metric tons, a minuscule amount of structure in the face of the more than 500 metric tons of propellant the vehicle carries at liftoff.

These propellant loading tests can also be challenging for reasons aside from their highly explosive nature. Due to basic realities of the physical nature of metal, the predominate ingredient for Falcon 9’s load-bearing structures, metallic structures shrink under extreme cold (and expand under heating). In the case of Falcon 9’s massive 45 meters (150 foot) tall first stage, the scale of this contraction can be on the order of several inches or more, particularly given SpaceX’s predilection towards cooling their propellant as much as possible to increase its energy density. For Falcon 9, these issues (thermodynamic loads) are less severe. However, add in three relatively different first stage boosters linked together with several extremely strong supports at both their tops and bottoms and that dynamic loading can become a fickle beast. The expansion or compression of materials due to temperature changes can create absolutely astounding amounts of pressure – if you’ve ever forgotten a glass bottled drink in the freezer and discovered it violently exploded at some future point, you’ll have experienced this yourself.

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With several inches of freedom and the possibility that each Falcon Heavy booster might contract or expand slightly differently, these forces could understandably wreak havoc with the high precision necessary for the huge rocket to properly connect with the launch pad’s ground systems that transmit propellant, fluids, and telemetry back and forth. Information from two reliable Kennedy Space Center sources experienced with the reality of operating rockets, as well as NASASpaceflight.com, suggested that issues with dynamic loads (such as those created by thermal contraction/expansion) are a likely explanation for the delays, further evidenced by their observations that much of the pad crew’s attention appeared to be focused at the base of Transporter/Erector/Launcher (TEL). The TEL base hosts the clamps that hold the rocket down during static fires and launches, as well as the Tail Service Masts (TSMs) that connect with the Falcon 9/Heavy to transport propellant and data to the first stage(s). These connection points are both relatively tiny, mechanically sensitive, and absolutely critical for the successful operation of the rocket, and thus are a logical point of failure in the event of off-nominal or unpredicted levels of dynamic stresses.

Test, launch, land, repeat.

All things considered, these difficulties demonstrate that even after months (even years) of relentless modeling, testing, remodeling, and retesting, rockets (and especially huge rockets like Falcon Heavy) are immensely complex, and even tiny mistakes can lead the vehicle to stray from its expected behavior. Quite simply, the reality of engineering only truly comes into play once hardware is fully in the loop, and it’s in this state that SpaceX has demonstrated again and again a distinct and elegant ability to learn from their hardware, rather than attempt to salve uncertainty with a neurotic and counterproductive level of statistical analysis, modelling, and documentation. The agile launch company still dabbles in those aspects when beneficial or necessary, but testing comes first in its importance.

The conclusion here, then, is that Falcon Heavy’s delays betray this aspect of SpaceX – a launch company that loves its fans, but also understands the need for cautious testing when it comes to new and untried rocket hardware. Whether Falcon Heavy succeeds or fails, SpaceX will learn from the proceedings, and they will be better off for it (although maybe less so financially…).

Follow along live as launch photographer Tom Cross and I cover these exciting proceedings as close to live as possible.

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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 Starship Flight 13 aborted at Zero and Musk just told us what broke

Four Raptor engines failed to ignite at T-zero, forcing SpaceX to scrub Starship Flight 13 Thursday.

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SpaceX scrubbed the Starship Flight 13 launch attempt Thursday evening at the last possible moment, after four of the Super Heavy booster’s 33 Raptor 3 engines failed to ignite during the startup sequence. The 90-minute window had opened at 6:45 p.m. EDT from Starbase in Boca Chica, Texas, and the countdown had proceeded without issue all day, with more than 11.5 million pounds of liquid methane and liquid oxygen being fully loaded into the rocket before the automated abort triggered. SpaceX’s launch directors posted on X, “Standing down from today’s flight test attempt,” and shut down the livestream shortly after.

Musk confirmed the root cause within hours. “Some of the engines didn’t start, triggering an automatic launch abort,” he wrote on X. “To be confident of a good flight, 2 Raptors will be removed and replaced. Most probable launch timing is early next week.” SpaceX engineers began draining propellant tanks immediately and Booster 20 was rolled back to its hangar for inspection.

SpaceX comes with a slew of changes for Starship Flight 13

 

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The timing adds a layer of significance that did not exist during any of the previous 12 Starship flights. This is the first time SpaceX has attempted to launch Starship since the company made its stock market debut in June, listing under ticker SPCX at $135 per share. Public investors are now watching every Starship outcome in real time, and a last-second abort carries more visibility than it would have six months ago.

Flight 13 was designed to be one of the most consequential tests in the program’s history. It was set to carry 20 Starlink V3 satellites, the first operational payload Starship has ever attempted to deploy. Six of those satellites carried external cameras to photograph Starship’s heat shield from the outside during flight, which would act as a self-inspection approach SpaceX has never attempted before. The mission also needed to complete a Raptor engine relight in space, a step SpaceX skipped on Flight 12 in May after losing an engine during ascent. That Flight 12 booster also flipped 90 degrees off course during its boostback burn when five engines failed to reignite.

SpaceX has not announced an official next launch date. Musk’s “early next week” window points to July 21 or 22 at the earliest, pending the engine swap and a return to the pad.

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Elon Musk secretly acquires $1B energy company to power the AI future

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Gage Skidmore, CC BY-SA 4.0 , via Wikimedia Commons

Elon Musk flew under the radar with his recent purchase of a $1 billion energy company, according to Federal Trade Commission (FTC) documents.

Transaction number 202612350 listed Tesla and SpaceX frontman Elon Musk as the acquiring party and CF APR Super Holdings LLC as the seller, with New APR Energy, LLC as the acquired entity. The deal, which closed without public announcement, came to light on May 14.

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Analysts inferred the deal’s scale from minority stakeholder disclosures, including one report of a 5 percent interest sold for approximately $50.4 million. Fortress Investment Group had purchased APR’s assets in late 2024, rebranded the operation as New APR Energy, and subsequently transferred ownership to Musk.

APR Energy specializes in rapidly deployable power infrastructure. The company maintains one of the world’s largest fleets of mobile gas and diesel turbines, with more than 1.1 gigawatts of generation capacity. Its modular units, which are often trailer-mounted, enable turnkey installations ranging from 20 MW to over 500 MW.

Elon Musk admits he was ‘clearly wrong’ about Anthropic

APR provides full engineering, procurement, construction, operation, and maintenance services for behind-the-meter power plants, serving everything from data centers, utilities, and industrial clients.

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The firm has expanded aggressively to meet surging demand, recently adding turbines and deploying over 100 MW for a major AI hyperscaler. Its solutions bridge critical gaps where grid interconnections face delays of two to five years, according to Yahoo.

The acquisition means something more for Musk. As he continues to expand projects in artificial intelligence, especially xAI, his AI venture, there is a greater need to supply energy-intensive supercomputing clusters, including the Colossus project, with what they need: reliable and high-capacity power.

Ownership of APR provides immediate access to flexible generation assets that can be deployed adjacent to data centers, reducing dependence on a strained infrastructure. It also complements Tesla’s energy storage business, so Musk will be able to pull from his own entities to address the rapid scaling demands of AI training and compute.

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Tesla has to fix a big problem with its old headlights, NHTSA says

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tesla model 3 first generation headlight
Credit: Tesla Asia/Twitter

Tesla had a petition protesting a recall to fix a potential issue with 2017-2023 Model Y and Model 3 vehicles’ headlights was denied, as the National Highway Traffic Safety Administration (NHTSA) disagreed with the company’s opinion of things.

The recall covers approximately 19,917 Model Y and Model 3 vehicles built from 2017 to 2023. Tesla initially submitted a noncompliance report for the headlights on these vehicles on March 15, 2024. Tesla then petitioned for an exemption from the fix, which violated FMVSS No. 108 (40 CFR 571.108), arguing that the “noncompliance is inconsequential as it relates to motor vehicle safety.

The NHTSA disagreed, stating that Tesla’s conclusion that the headlights do not increase any risk was not an opinion it shared. The agency said it disagreed with Tesla’s assumption that glare is not increased to surrounding traffic. This issue could be highlighted even more in certain weather conditions.

Tesla will be required to remedy the issue, the NHTSA ruled:

“In consideration of the foregoing, NHTSA has decided that Tesla has not met its burden of persuasion that the subject FMVSS No. 108 noncompliance is inconsequential to motor vehicle safety. Accordingly, Tesla’s petition is hereby denied, and Tesla is consequently obligated to provide notification of and free remedy for that noncompliance under 49 U.S.C. 30118 and 30120.”

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The issue here appears to be the angle of the headlights and the brightness they emit during operation. The NHTSA report states that:

“Tesla’s headlamp supplier, Marelli Automotive Lighting, tested 25 right-hand and 25 left-hand lamps, and for this sample, found the maximum photometric intensity measured in the 10°U to 90°U and 90°L to 90°R zone was between 136.2 cd and 230.1 cd for the right-hand lamps and between 117.5 cd and 160.3 cd for the left-hand lamps. According to Tesla, these tests revealed that the photometric intensity of the right-hand and left-hand headlamp lower beam on the subject vehicles may measure as much as 230.1 cd in the 10°U to 90°U and 90°L to 90°R zone, exceeding the maximum photometric intensity by 105.1 cd. Additionally, Tesla states that a left-hand lamp tested by a Transport Canada recognized laboratory measured a maximum of 171.27 cd in the 10°U to 90°U and 90°L to 90°R zone. Despite these measurements exceeding the allowed photometric maximum of 125 cd, Tesla believes that the subject noncompliance is inconsequential to motor vehicle safety.”

Tesla also argued at some points that the headlights had not been deemed responsible for any complaints, accidents, or injuries related to the noncompliance.

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