SpaceX
SpaceX’s first dedicated Starlink launch announced as mass production begins
SpaceX has announced a launch target of May 2019 for the first batch of operational Starlink satellites in a sign that the proposed internet satellite constellation has reached a major milestone, effectively transitioning from pure research and development to serious manufacturing.
R&D will continue as SpaceX Starlink engineers work to implement the true final design of the first several hundred or thousand spacecraft, but a significant amount of the team’s work will now be centered on producing as many Starlink satellites as possible, as quickly as possible. With anywhere from 4400 to nearly 12,000 satellites needed to complete the three major proposed phases of Starlink, SpaceX will have to build and launch a minimum of ~2200 satellites in the next five years, averaging 37 high-performance, low-cost spacecraft built and launched every month for the next 60 months.
A shift in the Stars
Despite the major challenges ahead of SpaceX, things seem to be going quite smoothly with the current mix of manufacturing and development. As previously reported on Teslarati, SpaceX CEO Elon Musk forced the Starlink group through a painful reorganization in the summer of 2018, challenging the remaining leaders and their team to launch the first batch of operational Starlink satellites no later than June 2019. As a consequence, a sort of compromise had to be reached where one additional group of quasi-prototype satellites would be launched before settling on a truly final design for serious mass-production.
According to SpaceX filings with the FCC, the first group of operational satellites – potentially anywhere from 75 to 1000 or more – will rely on just one band (“Ku”) for communications instead of the nominal two (“Ku” and “Ka”), a change that SpaceX says will significantly simplify the first spacecraft. By simplifying them, SpaceX believes it can expedite Starlink’s initial deployment without losing a great deal of performance or interfering with constellations from competitors like OneWeb.
Somewhere along the line, SpaceX would iteratively improve each subsequent ‘generation’ of Starlink satellites until they reached the nominal performance characteristics outlined in the company’s original constellation application. Knowing SpaceX, improvements would continue for as long as lessons continued to be learned from operating hundreds and eventually thousands of orbital spacecraft.
As one concrete example, recent SpaceX FCC documents stated that the first 75 Starlink spacecraft would feature a less-optimized reentry design, meaning that a select few components will not entirely burn up during reentry, creating debris that poses a
While the FCC has yet to grant SpaceX’s requested modifications, the other major goal is to reduce the operating orbit of the first phase of 1584 satellites to 550 km (340 mi), a change that SpaceX says will drastically reduce the potential lifespan of any orbital debris in the unlikely event of their creation. A lower altitude also places a major cushion between SpaceX’s first ~1500 satellites and the orbits of several other planned constellations, including OneWeb and Telesat.
Hello, Production Hell, my old friend
Meanwhile, SpaceX’s Starlink program has begun the often painful steps of transitioning from a venture primarily focused on research and development to one focused mainly on building production lines and supply chains and manufacturing hardware. SpaceX’s Starlink facilities are currently housed in three nearby buildings located in Redmond, Washington, likely offering approximately 150,000 square feet (14,000 m^2) for a mix of office, development, and production spaces. At least one of the three non-office buildings could potentially become dedicated to production while one building – approximately 40,000 ft^2 (~3500 m^2) – has already been completely transformed into a prototype of a Starlink satellite production line, supporting manufacturing for first several dozen quasi-prototype spacecraft. For reference,
Mass-producing spacecraft at the scale needed to build even half of those needed for the first phase of ~4400 Starlink satellites will be a feat unprecedented in the history of the space industry. Barring FCC exemptions (possible but unlikely), SpaceX needs to launch ~2200 Starlink satellites between now and April 2024. To complete the first phase, the final number of satellites rises to ~4400. Adding on a proposed constellation of very low Earth orbit (
Perhaps SpaceX will be able to garner invaluable insight from the lessons its sister company learned during Model 3’s torturous “production hell”, in which the car company had to grow its production volume by almost a magnitude as quickly as possible. Ironically, it may even be the case that SpaceX has the easier task relative to Tesla.
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SpaceX and its CEO Elon Musk are starting to shed some light on the potential reasoning for the loss of Starship yesterday, which was lost after a successful launch and catch of the lower-stage booster.
Starship was lost during its ascension, and debris rained down over the Caribbean less than an hour after SpaceX lost all communication with the spacecraft.
A few hours after the launch was over, SpaceX started to shed some light after looking at preliminary data that the rocket left behind.
The company said that a fire developed in the aft section of Starship:
“Following stage separation, the Starship upper stage successfully lit all six Raptor engines and performed its ascent burn to space. Prior to the burn’s completion, telemetry was lost with the vehicle after approximately eight and a half minutes of flight. Initial data indicates a fire developed in the aft section of the ship, leading to a rapid unscheduled disassembly with debris falling into the Atlantic Ocean within the predefined hazard areas.”
Additionally, Musk said that there was some sort of oxygen or fuel leak in the cavity above the ship engine firewall.
The leak was evidently large enough to build more pressure than the vent was able to handle:
🚨Elon Musk has also said an oxygen or fuel leak in the cavity above the ship engine firewall could be the cause of the anomaly. https://t.co/BgLkdA9Kk1
— TESLARATI (@Teslarati) January 17, 2025
Some also seemed to recognize evidence of fires throughout the flight of Starship, which is obviously an anomaly:
Unconfirmed but what looks to be fire at the hinge of Starship’s flap. A potential RUD? We await as we get any confirmation from SpaceX.
They do not have comms with the spacecraft as this moment. pic.twitter.com/Cn1EF4AHpv
— Mihir Tripathy (@mihirneal) January 16, 2025
There will be more information regarding the loss of Starship in the coming days and weeks, but Musk already believes that a bit of fire suppression and more volume in the cavity above the ship engine firewall could fix the issue.
“Nothing so far suggests pushing next launch past next month,” he said, so Flight 8 could happen sometime in February.
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SpaceX completed its seventh launch of Starship on Thursday, accomplishing a clean liftoff and catch of the first-stage booster. However, the upper stage was lost after its ascent.
The launch took place just a few minutes after 5 p.m. on the East Coast, as the first attempts at getting Starship in the air for the seventh time were delayed by weather both last week and this week.
Conditions were favorable on Thursday as SpaceX looked to follow up a successful campaign by Blue Origin, Jeff Bezos’s company, earlier today.
SpaceX went into the seventh Starship launch with plans for a catch attempt of the first-stage booster, something it attempted and completed during the fifth test launch last year. It decided to skip a catch attempt with the sixth test flight as conditions were not aligned.
For now, SpaceX is extremely selective as to when it attempts catches.
However, it was successful during this attempt, its second completed catch:
🚨 🚀 Here is @SpaceX’s full catch of the Lower Stage Booster from Starship Flight 7! pic.twitter.com/IXIRAGr1Md
— TESLARATI (@Teslarati) January 16, 2025
This flight differed from previous launches as SpaceX rolled out several improvements to the rocket and the processes as it featured plans to do a Starlink deployment simulation and had various adjustments to flap placement and avionics.
These plans were disrupted by the fact that SpaceX lost all communications with Starship about ten minutes into the flight, which the aerospace company confirmed was a result of losing the spacecraft sometime during its ascent.
🚀🚨 Telemetry on Starship has been lost. All comms with the ship have been lost, and SpaceX’s livestream says this is an “anomaly.”
“We are assuming the ship has been lost.” pic.twitter.com/fyyCNuXVRg
— TESLARATI (@Teslarati) January 16, 2025
Although the catch was successful, the loss of the actual rocket seemed to be a huge damper on the entire event. SpaceX confirmed several minutes after the loss of communications that the rocket was destroyed and was lost.
It was its first failure since the second Starship launch in November 2023. SpaceX had no answers for why the rocket was destroyed and lost.
We will keep you updated in the coming days.
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SpaceX has confirmed a new target date for the seventh Starship test launch after weather in Texas delayed the first scheduled date for “three or four days.”
The company is now targeting the launch for Monday, January 13, at 4 p.m. CST or 5 p.m. EST. The launch date is not set in stone as any variety of delays could impact this, but SpaceX hopes to finally take off after a delay that pushed it back from January 10.
🚨 STARSHIP LAUNCH DATE: @SpaceX says Starship’s 7th test flight is now targeted for Monday, January 13 at 4pm CST
— TESLARATI (@Teslarati) January 8, 2025
What’s new with this Starship launch
With this being the seventh test launch of Starship, there are several things that the company will change and hope to accomplish. All of these launches are done in preparation for eventually taking flight to Mars, something that will happen next year, according to CEO Elon Musk.
First, SpaceX is rolling out a next-generation ship with “significant upgrades.” Forward flaps have been made smaller and are repositioned away from the heat shield, which will “reduce their exposure to reentry heating.”
There is also a 25 percent increase in propellant volume, a new fuel feedline system for the Raptor vacuum engines, and a better-than-ever propulsion avionics module that will control the valves and reading sensors.
Avionics, as a whole, underwent a redesign and now have more capability and redundancy for missions as they become more complex.
Starlink test
SpaceX is also planning to deploy 10 Starlink simulators that are similar in size and weight to the next-generation Starlink satellites:
“While in space, Starship will deploy 10 Starlink simulators, similar in size and weight to next-generation Starlink satellites as the first exercise of a satellite deploy mission. The Starlink simulators will be on the same suborbital trajectory as Starship, with splashdown targeted in the Indian Ocean. A relight of a single Raptor engine while in space is also planned.”
Ship return and catch
There will be several experiments that have to do with returning Starship and various catch scenarios and sequences. One of which will see “a significant number of tiles be removed to stress-test vulnerable areas across the vehicle.”
The ship’s reentry profile was also intentionally designed to test the structural limits of the flaps while at the point of maximum dynamic pressure during reentry.
Currently, SpaceX did not detail whether it would attempt another catch during this test launch. These are usually game-time decisions.
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