Hardware

Launch vehiclesedit

Falcon 1 was a small rocket capable of placing several hundred kilograms into low Earth orbit. It functioned as an early test-bed for developing concepts and components for the larger Falcon 9. Falcon 1 attempted five flights between 2006 and 2009. With Falcon I, when Musk announced his plans for it before a subcommittee in the Senate in 2004, he discussed that Falcon I would be the 'worlds only semi-reusable orbital rocket' apart from the Space Shuttle. On September 28, 2008, on its fourth attempt, the Falcon 1 successfully reached orbit, becoming the first privately funded, liquid-fueled rocket to do so.

Falcon 9 is an EELV-class medium-lift vehicle capable of delivering up to 22,800 kilograms (50,265 lb) to orbit, and is intended to compete with the Delta IV and the Atlas V rockets, as well as other launch providers around the world. It has nine Merlin engines in its first stage. The Falcon 9 v1.0 rocket successfully reached orbit on its first attempt on 2010-06-04. Its third flight, COTS Demo Flight 2, launched on 2012-05-22, and was the first commercial spacecraft to reach and dock with the International Space Station. The vehicle was upgraded to Falcon 9 v1.1 in 2013, Falcon 9 Full Thrust in 2015, and finally to Falcon 9 Block 5 in 2018. As of 23 March 2020update, the Falcon 9 family has flown 84 successful missions with one failure, one partial success, and one vehicle destroyed during a routine test several days prior to a scheduled launch.

In 2011, SpaceX began development of the Falcon Heavy, a heavy-lift rocket configured using a cluster of three Falcon 9 first stage cores with a total of 27 Merlin 1D engines and propellant crossfeed. The Falcon Heavy successfully flew on its inaugural mission on February 6, 2018, with a payload consisting of Musk's personal Tesla Roadster into heliocentric orbit The first stage would be capable of lifting 63,800 kilograms (140,660 lb) to LEO with the 27 Merlin 1D engines producing 22,819 kN of thrust at sea level, and 24,681 kN in space. At the time of its first launch, SpaceX described their Falcon Heavy as "the world's most powerful rocket in operation."

Rocket enginesedit

Since the founding of SpaceX in 2002, the company has developed three families of rocket engines—Merlin and the retired Kestrel for launch vehicle propulsion, and the Draco control thrusters. SpaceX is currently developing two further rocket engines: SuperDraco and Raptor. SpaceX is currently the world's most prolific producer of liquid fuel rocket engines. Merlin is a family of rocket engines developed by SpaceX for use on their launch vehicles. Merlin engines use LOX and RP-1 as propellants in a gas-generator power cycle. The Merlin engine was originally designed for sea recovery and reuse. The injector at the heart of Merlin is of the pintle type that was first used in the Apollo Program for the lunar module landing engine. Propellants are fed via a single shaft, dual impeller turbo-pump. Kestrel is a LOX/RP-1 pressure-fed rocket engine and was used as the Falcon 1 rocket's second stage main engine. It is built around the same pintle architecture as SpaceX's Merlin engine but does not have a turbo-pump, and is fed only by tank pressure. Its nozzle is ablatively cooled in the chamber and throat, is also radiatively cooled, and is fabricated from a high strength niobium alloy. Both names for the Merlin and Kestrel engines are derived from species of North American falcons: the American kestrel and the merlin.

Draco engines are hypergolic liquid-propellant rocket engines that utilize monomethyl hydrazine fuel and nitrogen tetroxide oxidizer. Each Draco thruster generates 400 newtons (90 lbf) of thrust. They are used as reaction control system (RCS) thrusters on the Dragon spacecraft. SuperDraco engines are a much more powerful version of the Draco thrusters, which were initially meant to be used as landing and launch escape system engines on Dragon 2. The concept of using retro-rockets for landing was scrapped in 2017 when it was decided to perform a traditional parachute descent and splashdown at sea. Raptor is a new family of methane-fueled full-flow staged combustion cycle engines to be used in its future Starship launch system. Development versions were test-fired in late 2016. On April 3, 2019, SpaceX conducted a successful static fire test in Texas on its Starhopper vehicle, which ignited the engine while the vehicle remained tethered to the ground. On July 24, 2019, SpaceX conducted a successful test hop of 20 meters of its Starhopper. On August 28, 2019, Starhopper conducted a successful test hop of 150 meters.

Dragon spacecraftedit

In 2005, SpaceX announced plans to pursue a human-rated commercial space program through the end of the decade. The Dragon is a conventional blunt-cone ballistic capsule that is capable of carrying cargo or up to seven astronauts into orbit and beyond. In 2006, NASA announced that the company was one of two selected to provide crew and cargo resupply demonstration contracts to the ISS under the COTS program. SpaceX demonstrated cargo resupply and eventually crew transportation services using the Dragon. The first flight of a Dragon structural test article took place in June 2010, from Launch Complex 40 at Cape Canaveral Air Force Station during the maiden flight of the Falcon 9 launch vehicle; the mock-up Dragon lacked avionics, heat shield, and other key elements normally required of a fully operational spacecraft but contained all the necessary characteristics to validate the flight performance of the launch vehicle. An operational Dragon spacecraft was launched in December 2010 aboard COTS Demo Flight 1, the Falcon 9's second flight, and safely returned to Earth after two orbits, completing all its mission objectives. In 2012, Dragon became the first commercial spacecraft to deliver cargo to the International Space Station, and has since been conducting regular resupply services to the ISS.

In April 2011, NASA issued a $75 million contract, as part of its second-round commercial crew development (CCDev) program, for SpaceX to develop an integrated launch escape system for Dragon in preparation for human-rating it as a crew transport vehicle to the ISS. In August 2012, NASA awarded SpaceX a firm, fixed-price SAA with the objective of producing a detailed design of the entire crew transportation system. This contract includes numerous key technical and certification milestones, an uncrewed flight test, a crewed flight test, and six operational missions following system certification. The fully autonomous Crew Dragon spacecraft is expected to be one of the safest crewed spacecraft systems. Reusable in nature, the Crew Dragon will offer savings to NASA. SpaceX conducted a test of an empty Crew Dragon to ISS in early 2019, and later in the year, they plan to launch a crewed Dragon which will send US astronauts to the ISS for the first time since the retirement of the Space Shuttle. In February 2017, SpaceX announced that two would-be space tourists had put down "significant deposits" for a mission which would see the two tourists fly on board a Dragon capsule around the Moon and back again.

In addition to SpaceX's privately funded plans for an eventual Mars mission, NASA Ames Research Center had developed a concept called Red Dragon: a low-cost Mars mission that would use Falcon Heavy as the launch vehicle and trans-Martian injection vehicle, and the Dragon capsule to enter the Martian atmosphere. The concept was originally envisioned for launch in 2018 as a NASA Discovery mission, then alternatively for 2022. The objectives of the mission would be to return the samples from Mars to Earth at a fraction of the cost of the NASA own return-sample mission now projected at 6 billion dollars. In September 2017, Elon Musk released first prototype images of their spacesuits to be used in future missions. The suit is in the testing phase and it is designed to cope with 2 atm (200 kPa; 29 psi) pressure in vacuum. The Crew Dragon spacecraft was first sent to space on March 2, 2019.

On March 27, 2020, SpaceX revealed the Dragon XL resupply spacecraft to carry pressurized and unpressurized cargo, experiments and other supplies to NASA's planned Lunar Gateway under a Gateway Logistics Services (GLS) contract. The equipment delivered by Dragon XL missions could include sample collection materials, spacesuits and other items astronauts may need on the Gateway and on the surface of the Moon, according to NASA. It will launch on SpaceX Falcon Heavy rockets from pad 39A at the Kennedy Space Center in Florida. The Dragon XL will stay at the Gateway for six to 12 months at a time, when research payloads inside and outside the cargo vessel could be operated remotely, even when crews are not present. Its payload capacity is expected to be more than 5,000 kilograms (11,000 lb) to lunar orbit.

Reusable launch systemedit

SpaceX's reusable launcher program was publicly announced in 2011 and the design phase was completed in February 2012. The system returns the first stage of a Falcon 9 rocket to a predetermined landing site using only its own propulsion systems.

SpaceX's active test program began in late 2012 with testing low-altitude, low-speed aspects of the landing technology. The prototypes of Falcon 9 performed vertical takeoffs and landings.

High-velocity, high-altitude aspects of the booster atmospheric return technology began testing in late 2013 and have continued through 2018, with a 98% success rate to date. As a result of Elon Musk's goal of crafting more cost-effective launch vehicles, SpaceX conceived a method to reuse the first stage of their primary rocket, the Falcon 9, by attempting propulsive vertical landings on solid surfaces. Once the company determined that soft landings were feasible by touching down over the Atlantic and Pacific Ocean, they began landing attempts on a solid platform. SpaceX leased and modified several barges to sit out at sea as a target for the returning first stage, converting them to autonomous spaceport drone ships (ASDS). SpaceX first achieved a successful landing and recovery of a first stage in December 2015, and in April 2016, the first stage booster first successfully landed on the ASDS Of Course I Still Love You.

SpaceX continues to carry out first stage landings on every orbital launch that fuel margins allow. By October 2016, following the successful landings, SpaceX indicated they were offering their customers a ten percent price discount if they choose to fly their payload on a reused Falcon 9 first stage. On March 30, 2017, SpaceX launched a "flight-proven" Falcon 9 for the SES-10 mission. This was the first time a re-launch of a payload-carrying orbital rocket went back to space. The first stage was recovered and landed on the ASDS Of Course I Still Love You in the Atlantic Ocean, also making it the first landing of a reused orbital class rocket. Elon Musk called the achievement an "incredible milestone in the history of space."

The autonomous spaceport drone ships are named after giant starships from the Culture series stories by science fiction author Iain M. Banks.

Starshipedit

SpaceX is developing a super-heavy lift launch system, Starship. Starship is a fully reusable second stage and space vehicle intended to replace all of the company's existing launch vehicle hardware by the early 2020s; plus ground infrastructure for rapid launch and relaunch and zero-gravity propellant transfer technology in low Earth orbit (LEO).

SpaceX initially envisioned a 12-meter-diameter ITS concept in 2016 which was solely aimed at Mars transit and other interplanetary uses. In 2017, SpaceX articulated a smaller 9-meter-diameter BFR to replace all of SpaceX launch service provider capabilities—Earth-orbit, lunar-orbit, interplanetary missions, and potentially, even intercontinental passenger transport on Earth—but do so on a fully reusable set of vehicles with a markedly lower cost structure. A large portion of the components on Starship are made of 301 stainless steel. Private passenger Yusaku Maezawa has contracted to fly around the Moon in Starship in 2023.

Musk's long-term vision for the company is the development of technology and resources suitable for human colonization on Mars. He has expressed his interest in someday traveling to the planet, stating "I'd like to die on Mars, just not on impact." A rocket every two years or so could provide a base for the people arriving in 2025 after a launch in 2024. According to Steve Jurvetson, Musk believes that by 2035 at the latest, there will be thousands of rockets flying a million people to Mars, in order to enable a self-sustaining human colony.

Other projectsedit

In January 2015, SpaceX CEO Elon Musk announced the development of a new satellite constellation, called Starlink, to provide global broadband internet service. In June 2015, the company asked the federal government for permission to begin testing for a project that aims to build a constellation of 4,425 satellites capable of beaming the Internet to the entire globe, including remote regions that currently do not have Internet access. The Internet service would use a constellation of 4,425 cross-linked communications satellites in 1,100 km orbits. Owned and operated by SpaceX, the goal of the business is to increase profitability and cash flow, to allow SpaceX to build its Mars colony. Development began in 2015, initial prototype test-flight satellites were launched on the SpaceX PAZ mission in 2017. Initial operation of the constellation could begin as early as 2020. As of March 2017update, SpaceX filed with the US regulatory authorities plans to field a constellation of an additional 7,518 "V-band satellites in non-geosynchronous orbits to provide communications services" in an electromagnetic spectrum that had not previously been "heavily employed for commercial communications services." Called the "V-band low-Earth-orbit (VLEO) constellation", it would consist of "7,518 satellites to follow the earlier proposed 4,425 satellites that would function in Ka- and Ku-band". In February 2019, SpaceX formed a sibling company, SpaceX Services, Inc., to license the manufacture and deployment of up to 1,000,000 fixed satellite earth stations that will communicate with its Starlink system. In May 2019, SpaceX launched the first batch of 60 satellites aboard a Falcon 9 from Cape Canaveral, FL.

In June 2015, SpaceX announced that they would sponsor a Hyperloop competition, and would build a 1-mile-long (1.6 km) subscale test track near SpaceX's headquarters for the competitive events. The first competitive event was held at the track in January 2017, the second in August 2017 and the third in December 2018.