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SpaceX workers cap Starship with tank dome as Raptor arrivals and hop tests near

Starhopper had its upper propellant tank dome installed on Jan 24. Technicians continue to work inside the craft. (NASASpaceflight - bocachicagal)

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6 years ago

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SpaceX employees and local contractors continue to outfit the aft section of the first full-scale BFR prototype with a variety of important components, recently culminating in the installation of the Starship hopper’s top propellant tank dome,

Critical to the arrival and installation of its Raptor engines and the craft’s first hop tests, this work continues despite the premature demise of Starhopper’s apparently fragile nose cone (fairing), toppled on January 22nd when fairly mild winds of around 50 mph (80 km/h) encountered the shoddy rigging meant to keep the huge but lightweight hardware on its concrete stand.

As photos and the media fervor that ensued generally illustrate, the nose section certainly was not effectively held to its concrete stand, causing the insufficient rigging to break and the large sheet metal structure to unceremoniously collapse and fold in half under its own weight. While 50 mph (90 km/h) gusts are not insignificant, they are also fairly common, especially when located on the unprotected edge of the South Texas Coast in the middle of the winter.

Put in a slightly more direct fashion, building a complex structure outside without ensuring that it will be able to withstand the region’s average inclement weather would be an embarrassing oversight for even the most basic construction project, no less SpaceX’s first Starship prototype. It’s also possible that local construction contractors are being leaned on to complete an aerospace-ish project they would likely have little practical experience with, in which case run-of-the-mill workplace miscommunication or a failure to double-check work (rigging) could have easily led to the fairing’s demise.

Regardless, what is done is done and whatever lessons were learned the hard way will hopefully prevent a repeat and encourage better workmanship throughout the project.

Capping the Starhopper

With the crumpled fairing section now beginning repairs under SpaceX’s lone on-site tent, SpaceX workers and contractors got back to the (available) tasks at hand and took another step towards Starhopper’s completion, installing the craft’s topmost propellant tank dome and effectively ‘capping’ the most important segment of the prototype.

Recently described by SpaceX CEO Elon Musk as a “fairing”, the upper section of Starhopper can presumably be compared with Falcon fairings, while the aft half – to feature two common-dome propellant tanks and an engine section with three Raptors – is likely roughly equivalent with Falcon 9 or Falcon Heavy boosters. For Falcon, fairings are dramatically less valuable than boosters (or upper stages) and far easier to produce. Aside from a collection of holes cut around its base, the nose section does appear to be more of an aerodynamic cap than anything with an active function, lending some credence to Musk’s claim that it “will take a few weeks to repair.”

After capping Starhopper’s tank and engine section, additional tank segments continued to be craned inside the aft section through the top dome’s large header gap, presumably allowing workers to finish up work while the craft is quite literally built around them, an undeniable method of saving time.

Up next, the most obvious milestone for Starhopper will be the static firing of its Raptor engines at SpaceX’s McGregor, Texas test facilities, followed soon after by the delivery of the first flight-worthy engines to Boca Chica for installation on the Starship prototype. Given Musk’s January 5th estimate that SpaceX was 4 to 8 weeks away from the first hop test and the Jan. 23rd addition of “a few weeks” to repair the craft’s nose section, it’s probably safe to expect Starhopper’s first hop tests to begin no earlier than (NET) mid-March. This should also give construction workers a welcome influx of time to complete the Falcon 9-class hopper’s first rough launch pad.

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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 and Elon Musk explain potential reasons for Starship loss

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2 months ago

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January 17, 2025

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Credit: SpaceX

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:

Some also seemed to recognize evidence of fires throughout the flight of Starship, which is obviously an anomaly:

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 completes second catch of lower stage, but loses Starship

Published

2 months ago

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January 16, 2025

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Credit: SpaceX

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:

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.

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 confirms next Starship launch target – Here’s when it will take off

Published

2 months ago

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January 9, 2025

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spacex starship upper stage catch
Credit: Elon Musk | X

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.

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.”

SpaceX eyes 25 annual Starship launches starting next year

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.

Need accessories for your Tesla? Check out the Teslarati Marketplace:

Please email me with questions and comments at joey@teslarati.com. I’d love to chat! You can also reach me on Twitter @KlenderJoey, or if you have news tips, you can email us at tips@teslarati.com.

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