Updates

Falcon 9 Flight 1 in Pictures

Friday, June 18, 2010

Flight sequence for Falcon 9 Flight 1 as it departs from the SpaceX launch pad at Launch Complex 40, Cape Canaveral, Florida on June 4, 2010 with an official liftoff time of 2:45 PM Eastern / 11:45 AM Pacific / 18:45:00 UTC.

Unless otherwise noted, all image credits: SpaceX.

View from the second stage’s aft-facing camera, at T minus 10 seconds, looking down the length of the Falcon 9 rocket,
about 37 meters (120 feet) above the launch pad and main engines. The quick connect panel at left provides propellant,
power and communications to the second stage of the vehicle, and disconnects at liftoff. The code at lower left is UTC time.

At one second prior to liftoff, the nine Merlin 1C main engines reach full power, just before the launch
mount releases the vehicle for flight.

As it departs from the launch pad, the rising Falcon 9 passes the clamps located at the top of the transporter/erector structure.

Pieces of frost fall from the cryogenic liquid oxygen tanks, and look like fireworks when illuminated by the engines’ light.
Small white cylinders to left and right are the tops of two of the four lightning towers that surround and protect the launch pad.

The circular ring road that surrounds the launch site recedes as the rocket climbs.

A condensation shock front surrounds the vehicle as it climbs above a thin deck clouds. Insert has view from the ground
showing the full body condensation wave. Insert image credit: Ben Cooper, launchphotography.com / spaceflightnow.com

Passing the point of Maximum Dynamic Pressure (MaxQ). From this time onwards, the combination of decreasing atmospheric
pressure and increasing velocity will apply less and less force to the vehicle.

The exhaust plume darkens due to decreasing oxygen at this altitude, and expands due to the decreasing atmospheric pressure.

The exhaust plume reaches its maximum size just before first stage shutdown.

After first stage shutdown, the vehicle coasts for a moment before initiating stage separation.

Stage separation begins with the pneumatic pushers pushing the first stage away.

Stage separation exposes the nozzle extension of the second stage Merlin Vacuum engine.

Ignition of the second stage Merlin Vacuum engine.

The Merlin Vacuum fires without visible flame as we cross into the defined edge of space.

As the nozzle extension warms, it softens the adhesive that secures the four segments of the nozzle stiffening ring.
They release and fall away, similar to the event on SpaceX’s Falcon 1.

The vehicle remains on the designated flight path and continues climbing towards orbit.

Continuing to climb, the coast of Florida lies below the clouds at upper right.

Reaching orbital altitude and speed. The gold colored plate at left is the interior portion of the quick disconnect panel.

Upon Second stage Engine Cut Off (SECO), the Falcon 9 and Dragon spacecraft qualification unit reach low earth orbit!
The vehicle sent this final image just moments before loss-of-signal as it passes over the horizon as viewed from the launch site.

First Falcon 9 Test Launch Update

Friday, June 4, 2010

Today, SpaceX’s first Falcon 9 has successfully achieved Earth orbit. This has been a great day for SpaceX and a promising step forward for the US space program, as we make progress towards expanding the human presence in space.

Click here to watch video of the first successful flight of Falcon 9:

SpaceX extends special thanks to all of our long-time supporters, all our NASA, Government, and Commercial customers, and the United States Air Force and Cape Canaveral Air Force Station for their excellent, ongoing support.

Preparations For First Falcon 9 Test Launch

Tuesday, June 1, 2010

SpaceX is now targeting Friday, June 4th for its first test launch attempt of the Falcon 9 launch vehicle.

The primary schedule driver for the first Falcon 9 test launch has been certification of the flight termination system (FTS). The FTS ensures that Air Force Range safety officials can command the destruction of the vehicle should it stray from its designated flight path.

The successful liftoff of the recent GPS satellite launch last Thursday freed up the necessary range resources to process our final documentation, and we are now looking good for final approval of the FTS by this Friday, June 4th, just in time for our first launch attempt.

Today we completed end to end testing of the Falcon 9 as required by the Air Force Range and everything was nominal. Later this evening, we will finish final system connections for the FTS. Tomorrow we plan to rollout in the morning, and erect the vehicle in the afternoon. On Friday, the targeted schedule is as follows:

Friday 4 June 2010

Launch Window Opens: 11:00 AM Eastern / 8:00 AM Pacific / 1500 UTC
Launch window lasts 4 hours. SpaceX has also reserved a second launch day on Saturday 5 June, with the same hours.

As always, weather will play a significant role in our overall launch schedule. The weather experts at the Cape are giving us a 40% chance of “no go” conditions for both days of our window, citing the potential for cumulus clouds and anvil clouds from thunderstorms.

If the weather cooperates, SpaceX will provide a live webcast of the launch events, presently scheduled to begin 20 minutes prior to the opening of the launch window. Click here to visit our webcast page which will also be accessible from our home page the day of launch.

It’s important to note that since this is a test launch, our primary goal is to collect as much data as possible, with success being measured as a percentage of how many flight milestones we are able to complete in this first attempt. It would be a great day if we reach orbital velocity, but still a good day if the first stage functions correctly, even if the second stage malfunctions. It would be a bad day if something happens on the launch pad itself and we’re not able to gain any flight data.

If we have a bad day, it will be disappointing, but one launch does not make or break SpaceX as a company, nor commercial spaceflight as an industry. The Atlas rocket only succeeded on its 13th flight, and today it is the most reliable vehicle in the American fleet, with a record better than Shuttle.

Regardless of the outcome, this first launch attempt represents a key milestone for both SpaceX and the commercial spaceflight industry. Keep in mind the launch dates and times are still subject to change, so please check the webcast page above for updates to this schedule. We appreciate your ongoing support and we hope you will tune in on launch day.

Preparations for First Falcon 9 Launch

Thursday, May 6, 2010

As we continue to progress towards the first Falcon 9 launch from Cape Canaveral, certification of the flight termination system (FTS) and subsequent range availability remain the two primary schedule drivers.

Air Force Range safety requires the FTS system, which allows them to safely end the launch should the vehicle stray from its designated flight corridor. The system consists of a command receiver and an ordnance system designed to split the vehicle's fuel and liquid oxygen tanks in the event of an errant flight.

Static test firing of the Falcon 9 first stage, conducted at SpaceX's launch site, Cape Canaveral, Florida on March 13, 2010.
Credit: SpaceX / Chris Thompson.

SpaceX is working closely with Ensign Bickford to complete testing of the explosive elements of the FTS system, but there are other components, such as the FTS radios, antennas and the transponder that come from other suppliers as well. All of these components must be qualified specifically for our flight environments, so unfortunately, it is not simply a case of buying “off the shelf”.

FTS testing is an iterative process where the number of remaining tests depends on the results of previous tests, making it very difficult to predict a completion date. Once testing is complete, final data is submitted to SpaceX and Air Force Range safety officials for review and acceptance. Much of the range calendar for May is already reserved for other activities, so range availability will be a key factor in identifying a launch date. Fortunately the FTS is the last remaining significant milestone--the vehicle is otherwise ready for flight, so once we complete certification, we will be “all systems go” for launch.

Wet Dress Rehearsal

During our successful wet dress rehearsal (WDR) in late February, we experienced some problems with the thermal protective cork layer that covers the first stage. In some areas subjected to the extreme cold of liquid oxygen (LOX), the cork's bonding adhesive failed and several panels separated from the vehicle. It is important to emphasize that the cork is not needed for ascent and there is no risk to flight even if it all came off. This is for thermal protection on reentry to allow for the possibility of recovery and reuse. While stage recovery is not a primary mission objective on this inaugural launch, it is part of our long-term plans, and we will attempt to recover the first stage on this initial Falcon 9 flight.

After applying a new layer of cork thermal protection using a new adhesive system, we opted to perform a second wet dress rehearsal, as well as an electromagnetic interference (EMI) test. Everything performed well and the new adhesive remained properly bonded. A word of thanks to NASA and our resin supplier for helping our structures team find these effective solutions.

As we ramp up our flight rate, Florida will continue to be SpaceX's fastest growing region. We are entering continuous launch operations mode, meaning we will have over 100 people in Florida on average. That count may go as high as 200 later this year when we start preparing and launching Dragon. We expect our direct employment at the Cape to eventually reach thousands of people; using standard multipliers for indirect regional employment, this could mean in excess of several thousand jobs long term.

Presidential Visit

President Obama honored us with a visit to the SpaceX Falcon 9 launch site at Cape Canaveral on April 15, 2010, just prior to his national speech at Kennedy Space Center describing the administration's new space initiatives.

President Barack Obama and SpaceX CEO and CTO Elon Musk at the SpaceX Falcon 9
launch pad, Cape Canaveral, Florida on April 15, 2010. SpaceX's Leslie Woods Jr. and
NASA Administrator Charles Bolden in background. Credit: Associated Press.

Credit: Associated Press.

Meeting the President at the Falcon 9 launch site, from left: Neil G. Hicks, Florence Li, Brian Mosdell,
President Obama, Leslie Woods Jr., and Elon Musk. Credit: Getty Images.

Several members of our SpaceX team were able to meet the President during his tour of the Falcon 9 launch pad including:

Neil G. Hicks, SpaceX Lead Fluid System Engineer

Neil received his BS in Mechanical Engineering from the University of Florida and is a Florida Licensed Professional Engineer with 31 years experience. Neil spent 17 years as a NASA shuttle technician on the main engines, 13 years as a launch propulsion engineer involved in design and development of the Delta IV RS-68 rocket engine, and a year designing the Ares I launch pad pneumatic system for NASA. In the two and a half years since joining SpaceX, Neil has lead the team designing, building, and activating the launch pad fluid systems for Falcon 9.

Florence Li, SpaceX Structures Manager

Florence received her BS in Mechanical Engineering from the University of Delaware, and her MS in Aeronautics and Astronautics from Stanford University. Florence has been with SpaceX almost seven years. She started with structural analysis, testing and launch integration on the first four Falcon 1 rocket launch campaigns, and currently works on Falcon 9 vehicle integration at Cape Canaveral.

Brian Mosdell, SpaceX Director, Florida Launch Operations

Brian received his BS in Aeronautical Engineering from Embry Riddle Aeronautical University and brings over 20 years of launch operations experience, including work on the Titan, Delta, and Atlas programs. Brian was the Chief Launch Conductor for ULA prior to joining SpaceX two years ago.

Leslie Woods Jr., SpaceX Compensation and Human Resources Information Systems Manager

Leslie received his BS in Mechanical Engineering from Stanford University and has been with SpaceX for nearly five years. His diverse background in engineering, technical sales and recruiting has helped lead SpaceX's growth from 200 employees in 2006 to nearly 1,000 in 2010.

The President impressed us all with his level of understanding, and the nature of his questions. He clearly perceives both the challenges we face, as well as the opportunities for these new initiatives to become powerful economic engines.

Next: Falcon 9 Flight 2 -- The First NASA COTS Launch

Our second Falcon 9 flight, which will be the first launch under the NASA COTS program, will carry our first operational Dragon spacecraft to orbit. If all goes as planned, liftoff should occur a few months after the inaugural Falcon 9 flight.

This “COTS 1” Dragon will perform several orbits of the Earth, followed by reentry and splashdown off the coast of Southern California. We will gather performance data and retire significant amounts of risk on key spacecraft systems, including Draco thrusters, the Dragon communication systems, PICA-X high performance heat shield material, and other critical navigation, reentry, landing and recovery systems.

This first COTS mission will pave the way for the following COTS and CRS flights to demonstrate, and then actually provide, commercial cargo transport to and from the International Space Station in support of its continued growth and operation.

Falcon 9 Flight 2 -- Primary Structures

The largest sections of flight hardware for the second Falcon 9 flight — the 27 meter (89 foot) long first stage tank structure, and the shorter second stage tank — left our Hawthorne, California headquarters some weeks ago and have completed acceptance testing at our Texas Test Facility.

Installing the Falcon 9 Flight 2 second stage tank structure (white cylinder, top) and test interstage
(black cylinder, center) into the structural test stand at our Texas Test Facility. Subsequently, we
filled the stage with cryogenic nitrogen, then pressurized and tested it under a variety of load
conditions, qualifying it for flight. Credit: SpaceX.

We have completed primary fabrication of the carbon-composite interstage structure that join the two stages and houses the second stage's Merlin Vacuum engine during first stage flight. It has already passed structural acceptance testing, and after fitting it out with pneumatic collets, pushers, and other supporting hardware, it will ship to the Cape.

Looking “upwards” through the interstage for Falcon 9 Flight 2, shown undergoing final assembly in California. The four
black containers will house the parachutes that will help return the first stage to Earth after stage separation. Credit: SpaceX.

Falcon 9 Flight 2 -- Propulsion

The nine Merlin 1C first stage engines are undergoing final integration into the thrust structure assembly in Hawthorne, and will be shipped to Texas for mating with the first stage tank.

After integrating the nine Merlin 1C engines into the thrust structure
assembly it will be ready for shipment to Texas. Credit: SpaceX.

Each engine has already passed an individual acceptance test firing in Texas. After mating the nine-engine assembly to the first stage tank structure, it will be fired as a complete stage.

Second stage Merlin Vacuum engine for Falcon 9 Flight 2, preparing to
leave the Hawthorne factory
for Texas. Credit: SpaceX.

Similarly, the Merlin Vacuum engine for the second stage has shipped to Texas for testing at the engine level, to be followed by mating to the second stage tank and test firing as a complete stage.

The Merlin Vacuum engine's large radiatively cooled expansion nozzle for Falcon 9 Flight 2,
ready for final processing. It does not participate in the static test firing,
and will ship directly to the Cape. Credit: SpaceX.

Falcon 9 Flight 2 -- Dragon Spacecraft

Most significantly, the second flight of Falcon 9 will launch the first operational Dragon spacecraft into Earth orbit. After several trips around the Earth to verify its performance, it will reenter and splashdown off the coast of Southern California, to be met by our recovery team.

Mounted to the top of the Falcon 9's second stage, the Dragon spacecraft consists of a trunk section, a separate pressurized capsule section with integral service section around its base, and at the top, an aerodynamic nose cap that the vehicle jettisons after leaving the atmosphere.

Overview of Dragon spacecraft showing (from top) the nose cap, the cargo or crew carrying pressure vessel surrounded
by a service ring which holds propellant tanks, Draco thrusters, parachutes, etc, and trunk section which can
carry unpressurized cargo to orbit.

Draco Thruster Module Testing

Depending on its mission, each Dragon spacecraft will carry as many as 18 Draco thrusters for orbital maneuvering and attitude control. The SpaceX-developed Draco thrusters can generate up to 400 Newtons (90 pounds) of force. They can fire in bursts as short as a few milliseconds for precision maneuvering, or up to many minutes for changing orbital parameters and initiating the return to Earth.

Technicians produce Draco thrusters in the SpaceX Hawthorne propulsion clean room. With up to 18 Dracos per Dragon,
and with 17 Dragon missions currently on our launch manifest, we are manufacturing many thrusters per month. Credit: SpaceX.

Like the Merlin engines, each completed Draco undergoes an acceptance test firing before integration into the Dragon spacecraft. On Dragon, we mount the thrusters in groups of four and five, positioned to provide complete control of the spacecraft's direction of motion (X, Y and Z axis), as well as orientation (roll, pitch and yaw).

The video below shows a test of five Draco thrusters firing in various combinations and durations.

Testing a set of five Draco thrusters, conducted at our Texas Test Facility. Click to play video.

Four Draco thrusters fire to pull the Dragon spacecraft away from its expended trunk section in preparation for reentry. Credit: SpaceX.

Inspecting the first 18 flight Draco thrusters prior to their installation into the “COTS 1” Dragon spacecraft,
scheduled to fly on Falcon 9 Flight 2. Credit: SpaceX.

Dragon Propellant Tank Fabrication

The Dragon spacecraft carries a total of eight spherical titanium propellant tanks — four each for monomethyl hydrazine (MMH) fuel, and nitrogen tetroxide (NTO) oxidizer — the same as used for orbital maneuvering by the Space Shuttle. These propellants have long on-orbit lifetimes, permitting future Dragon flights to remain in space for a year or more. A system of valves provides redundant cross-connection between the propellant tanks for maximum reliability.

Like many other critical components, we found that the optimum path to maximum quality and lowest cost was to bring their production in-house. We take a flat circle of sheet titanium, mount it to a steel mandrel, then slowly rotate it while heating it to glowing, and then form it on to a hemispherical steel tool.

Spin-forming titanium sheet material into hemispheres. With a melting point of 1725 °C (3135 °F), we heat the metal to its plastic deformation point. Then a large metal wheel presses the softened metal around a steel hemisphere. Credit: SpaceX / Roger Gilbertson.

When cool, we remove the titanium hemisphere from the tool and finish it into final form. We then install the interior components, and weld a second hemisphere into place to make the finished spherical tank.

Technicians prepare a titanium hemisphere for installation of the interior components and welding of a second half
to make a complete propellant tank. Credit: SpaceX.

Dragon Trunk Separation Testing

At the end a Dragon mission's orbital phase, the spacecraft's thrusters fire to slow the craft and begin the return to Earth. Then, a set of dual-redundant electrically activated frangible nuts fire to release the trunk and expose the heat shield for reentry.

The trunk and pressurized sections of the Dragon spacecraft join together at six load-bearing mounts. The video below shows a full-scale test of the trunk separation system, using a qualification trunk, and with a steel structure suspended above simulating the Dragon's pressurized section.

Testing a set of pyrotechnic frangible nuts that release the trunk section from the Dragon spacecraft prior to start of reentry.
Click to play high-speed video.

Following separation, Draco thrusters fire to move the Dragon capsule away from the trunk, and reorient it into reentry position.

High Performance PICA-X Heat Shield

On a typical return, Dragon will enter into the Earth's atmosphere at around 7 kilometers per second (15,660 miles per hour), heating the exterior of the spacecraft as high as 2000 degrees Celsius (3632 degrees F).

However, just a few inches of SpaceX's PICA-X (Phenolic Impregnated Carbon Ablator) heat shield material will protect the spacecraft and keep its interior to a comfortable temperature.

Protected by a PICA-X heat shield, the Dragon spacecraft reenters the Earth's atmosphere at around 7 kilometers per second
(15,660 miles per hour), heating the exterior of the spacecraft as high as 2000 degrees Celsius (3620 degrees F). Credit: SpaceX.

Developed with the assistance of NASA, the originator of PICA, the “X” stands for the SpaceX-developed variants of the rigid, lightweight material, which have some improved properties and a greater ease of manufacture. Read more about PICA-X here.

We produce the PICA-X material in-house in large billets, then cut and machine them into separate tiles, each as large as a cafeteria tray, but over 8 cm (3 inches) thick, and weighing only about a kilogram (2.2 pounds) each. During reentry, less than 1 cm (1/2 inch) chars away from the surface of the PICA-X tiles, providing plenty of safety margin.

Inspecting a PICA-X tile prior to attachment to the heat shield assembly. We fabricate each strong,
lightweight tile to an exact shape for a precision fit to the carrier structure and its neighboring tiles. Credit: SpaceX.

Inspecting the carbon-composite carrier structure for the first Dragon spacecraft heat shield, fresh from its mold.
At nearly 4 meters (13 feet) in diameter, the structure supports the PICA-X tiles that protect the spacecraft during reentry. Credit: SpaceX.

Test placement of the flight PICA-X tiles on the first flight Dragon heat shield carrier structure. During reentry the lightweight
tiles withstand temperatures as high as 2000 degrees Celsius (3620 degrees F). Credit: SpaceX / Roger Gilbertson.

We have started final assembly of the first flight heat shield that will protect the Dragon spacecraft on its return. After fabrication and inspection, we attach the PICA-X tiles to the lens-shaped carbon-composite carrier structure, and fill the thermal expansion joints between tiles with a high-performance silicon compound.

From its inception, SpaceX designed the Falcon 9 and Dragon spacecraft to transport and return both cargo and astronauts. With 17 unmanned Dragon missions presently on our launch manifest, the Falcon 9 and Dragon spacecraft will have plenty of flight heritage by the time we carry our first crewmembers to orbit.

Now In Production -- Falcon 9 Flight 3

In addition, we have started production on Falcon 9 Flight 3 hardware and its Dragon spacecraft. We've completed fabrication of all six domes (three for first stage, three for second stage) and have started production of the tank barrel sections. We have the next ten Merlin engines in-process, components for the Dragon spacecraft pressure vessel formed, and many other elements under way.

Hardware for the third Falcon 9 flight in process in our Hawthorne factory, including first and second stage domes,
barrel segments, and Dragon capsule pressure vessel walls. Credit: SpaceX.

Our SpaceX team is nearing 1,000 members, and we're continuing to hire the most sought-after and enterprising engineers and production technicians seeking to make access to space regular, cost-effective and reliable. If you'd like to join our efforts in California, Texas, or Florida, please visit our Careers page.

Stay tuned for more updates as we progress towards the first flight of Falcon 9 and beyond.

Statement from Elon Musk

Thursday, April 15, 2010

Click here for April 15 statement from Elon Musk

Inaugural Falcon 9 / Dragon Flight Hardware Update

Sunday, March 14, 2010

On Saturday, March 13, SpaceX successfully completed a test firing of the inaugural Falcon 9 launch vehicle at Space Launch Complex 40 located at Cape Canaveral. Following a nominal terminal countdown, the launch sequencer commanded ignition of all 9 Merlin first stage engines for a period of 3.5 seconds.

Click image above to view close up video of SpaceX's successful Falcon 9 static fire.

Click image above for wide view video of SpaceX's successful Falcon 9 static fire.

Just prior to engine ignition, the pad water deluge system was activated providing acoustic suppression to keep vibration levels within acceptable limits. The test validated the launch pad propellant and pneumatic systems as well as the ground and flight control software that controls pad and launch vehicle configurations.

This was the final step for the rocket and launch pad before launch itself. We are now waiting for completion of the final set of tests of the flight termination system, specifically the explosives and initiators, and the acceptance of that test documentation by Air Force range safety. As soon as the tests are complete and the Air Force has signed off, we will move forward with launch.

If all goes as hoped, the first countdown attempt may be as soon as next month. It's important to note this is not a prediction of when we will launch, just when we will probably try a countdown. Additional images of SpaceX's successful Falcon 9 static fire below—stay tuned for more updates as we continue to progress towards the first flight of Falcon 9/Dragon.

Inaugural Falcon 9 / Dragon Flight Hardware Update

Thursday, March 11, 2010

On Tuesday, March 9th, SpaceX performed our first Static Fire for the Falcon 9 launch vehicle. We counted down to T-2 seconds and aborted on Spin Start (the process that fires the engines). Given that this was our first abort event on this pad, we decided to scrub for the day get a good look at the rocket before trying again.

The problem was pretty simple: our autostart sequence didn't issue the command to actuate (trigger) the ground side isolation valve to open. The ground side isolation valve releases ground-supplied high pressure helium to start the first stage engine turbopumps spinning at several thousand rpm. That generates enough pressure to start the gas generator, which is a small rocket engine that powers the turbopump. There are no vehicle side valves actuated for spin start (just check valves), so it is an all engines or none situation.

Ignition fluid flowing to the engines creating the green flame shown in this photo.

Ignition fluid (TEA-TEB) flowed nominally to all engines creating the green flame and the main valves opened, but no engines actually started and the system automatically aborted on lack of spin. The fire generated was from flushing the system of fuel and LOX from the open mains. No damage to the vehicle or ground systems and no other anomalies that need to be addressed.

Fire generated from the flushing of fuel and LOX, but no engines actually started.

We tested everything on the vehicle side exhaustively in Texas, but didn't have this iso valve on our test stand there. Definitely a lesson learned to make sure that *everything* is the same between test stand and launch pad on the ground side, not just on the vehicle side.

Despite the abort, we completed pad preps on time and with good execution. The integrated countdown with the range included holdfire checks, S- band telemetry, C-band, and Flight Termination System (FTS) simulated checks. We completed helium, liquid oxygen (LOX), and fuel loads to within tenths of a percent of T-zero conditions. Tanks pressed nominally and we passed all Terminal count, flight software, and ground software abort checks right down to T-2 seconds.

We detanked and safed the vehicle and launch pad. Preliminary review shows all other systems required to reach full ignition were within specification. All other pad systems worked nominally.

It is important to appreciate that what we are going through right now is the equivalent of “beta testing”. Problems are expected to occur, as they have throughout the development phase. The beta phase only ends when a rocket has done at least one, but arguably two or three consecutive flights to orbit.

Extreme weather at the Cape preventing additional static fire attempts

Right now, we are holding due to extreme weather. It is raining sideways at 46 mph and tornados have been spotted just north of the Cape. If all goes well, we will try the static fire again in the next few days.

Inaugural Falcon 9 / Dragon Flight Hardware Update

Thursday, February 25, 2010

SpaceX's Falcon 9 launch vehicle is now vertical at Space Launch Complex 40, Cape Canaveral! Click the image below to see the time lapse video:

The full flight-ready Falcon 9 launch vehicle with Dragon qualification spacecraft raised to vertical on the launch pad at SLC-40, Cape Canaveral, Florida. Credit: SpaceX.
Click to play video.

Taking the rocket vertical was the most recent milestone in a series of key launch prep activities at the Cape in recent weeks. Prior to this, SpaceX fully integrated all flight hardware, mating the first stage, second stage and Dragon qualification spacecraft in the SpaceX hangar at SLC-40.

Falcon 9 flight hardware undergoing final integration in the hangar at SpaceX's Cape Canaveral launch site in Florida. Components include: Dragon spacecraft qualification unit (l), second stage with Merlin Vacuum engine (ctr), first stage with nine Merlin 1C engines (r). Credit: SpaceX

Falcon 9 launch vehicle and Dragon spacecraft fully integrated in the SpaceX hangar at Space Launch Complex 40 (SLC-40) in Cape Canaveral, FL. Credit: Chris Thompson/SpaceX

We then raised the entire vehicle and placed it on to the mobile transporter. The following days involved connecting the vehicle to the transporter's support systems, including lines for RP-1 fuel, liquid oxygen (LOX), gaseous helium and nitrogen, as well as numerous electrical and data connections.

These attach to the vehicle through three umbilical connectors — two at the base of the first stage on opposite sides, and one at the top of the interstage that supplies the second stage. They remain connected until liftoff, when they detach and pull away from the departing vehicle, just as with the Falcon 1.

Credit: Chris Thompson/SpaceX

After verifying all the connections (leak checking the fluid and gas systems, and continuity checking the electrical systems), the team joined the entire flight-ready Falcon 9 to the launch support system for the first time. The process went very smoothly thanks to the efforts of our hardworking team down at the Cape.

Next, we opened the hangar doors and rolled the entire system out to the launch platform. There, we anchored to the launch mount, and connected the combined transporter/rocket to the ground-based feeds and support. We then conducted another set of system checks to verify those systems — the same set of liquids, gasses, electrical and data.

The full flight-ready Falcon 9 with Dragon qualification spacecraft rolls out of the SpaceX hangar at SLC-40, Cape Canaveral, Florida. Credit: SpaceX.
Click to play video.

Mounted on the mobile transporter, the full flight-ready Falcon 9 with Dragon qualification spacecraft rolls to the launch pad at SLC-40, Cape Canaveral, Florida. Credit: SpaceX.

On the morning of Saturday 20 February, we brought the vehicle to vertical, and began preparations for tanking and static test firing.

The full flight-ready Falcon 9 with Dragon qualification spacecraft stands
on the launch pad at SLC-40, Cape Canaveral, Florida. Credit: SpaceX.

Aerial view of Falcon 9 with Dragon qualification spacecraft on the launch pad at SLC-40,
Cape Canaveral, Florida. Credit: SpaceX.

The full flight-ready Falcon 9 with Dragon qualification spacecraft stands on the launch pad at SLC-40,
Cape Canaveral, Florida. Credit: Chris Thompson/SpaceX.

Coming up next, we prepare the vehicle and launch pad for static firing. During the test firing we will collect data from numerous sensors on and around the vehicle, then review all data thoroughly prior to launch.

Stay tuned for more updates as we continue to progress towards the first flight of Falcon 9.

Inaugural Falcon 9 / Dragon Flight Hardware Update

Monday, January 4, 2010

The SpaceX team kicked off 2010 with the successful full duration orbit insertion firing of the Falcon 9 second stage at our Texas test site (details below). This was the final stage firing required for launch, so the second stage will soon be packaged for shipment and should arrive at Cape Canaveral by end of month. Depending on how well full vehicle integration goes, launch should occur one to three months later.

2009 was an exciting year for SpaceX. In July, with the successful launch of RazakSAT, Falcon 1 became the first privately developed liquid fuel rocket to put a commercial satellite in orbit. That same month, DragonEye — SpaceX's Laser Imaging Detection and Ranging (LIDAR) sensor — launched on NASA's STS-127 shuttle mission and successfully completed flight system trials in preparation for guiding the Dragon spacecraft as it approaches the International Space Station. We also hosted the first astronaut training day at our Hawthorne headquarters in preparation for flights to the Space Station.

Last year also saw the successful arc jet testing of PICA-X, SpaceX's high performance heat shield material developed in collaboration with NASA, which will be used to protect our Dragon spacecraft on reentry. And our Merlin Vacuum engine demonstrated the highest efficiency ever for an American hydrocarbon rocket engine. SpaceX also signed deals with several key customers, including CONAE (Argentina's National Commission on Space Activity), Astrium and Orbcomm.

The ongoing evolution of the commercial space industry was recently featured as the cover story (“The New Space Rush”) in Popular Science magazine. The article provided a great perspective on the industry as a whole, but I disagree with the subheading, “Who Needs NASA?”. If you read the article, it's clear their intent was just to convey excitement for the developments in commercial space, but obviously NASA is and always will be critical to the future of space exploration, particularly at the outer edge where there is no commercial market. Without NASA, SpaceX certainly would not be where it is today.

As we get closer to our first Falcon 9 launch, SpaceX would like to thank NASA, the Air Force, the FAA, and our commercial customers for their continued support. And, of course, I would like to thank the whole SpaceX team for their unwavering commitment to our company and our mission, especially over these last few months. Through their hard work and dedication, 2010 promises to be another great year.

--Elon--

Falcon 9 First Stage

Prior to arrival at the Cape, the Falcon 9 first stage arrived at our Texas Test Site. There, we did a full checkout, raised it up to the top of the 72 meter (235 foot) tall test stand, and conducted two successful nine engine test firings — the first 10 seconds long, followed by a 30 second long firing three days later.

Test firing of the full flight first stage of Falcon 9, conducted Oct 16, 2009 at the SpaceX Texas Test Facility in McGregor.
Click to play video, and note the engines gimballing (steering) in the upper left camera.

Everything performed as planned; we then shipped the first stage to Florida and have commenced final processing in the hangar at the SpaceX launch site. Once all propulsion and avionics checkout processes are complete, we will move forward with stage mate, to be followed closely by vehicle transfer to the transporter erector, and a static fire shortly thereafter.

Falcon 9 first stage arriving in the hangar at Space Launch Complex 40, Cape Canaveral, Florida.
Photo credit: SpaceX.

Falcon 9 Second Stage

Flight hardware for the Falcon 9 second stage also shipped to Texas, where it completed static load testing, and then was integrated with the previously tested Merlin Vacuum second stage engine. After performing system checkouts, we raised the stage up on to the newly completed Upper Stage test stand.

Installing the Falcon 9 second stage into the newest test stand at our Texas test site.
Photo credit: Chris Thompson, SpaceX.

In November we conducted the initial second stage test firing lasting forty seconds. This test involved a new test stand, a new flight stage, and it occurred as planned, on the first attempt without aborts or recycles.

First test firing of the full flight second stage of Falcon 9, conducted at the SpaceX Texas Test Facility in McGregor.

On January 2, 2010, the team completed a full duration orbit insertion firing (329 seconds) of the integrated Falcon 9 second stage. At full power, the Merlin Vacuum engine generates 411,000 N (92,500 lbs force) of thrust, and operates with the highest performance ever for an American-made hydrocarbon rocket engine.

Full duration orbit insertion firing of the Falcon 9 second stage, conducted on January 2, 2010. Click to play video.
(Click to play video)

Having multiple stands for testing individual engines, first and second stages, and Draco thrusters allows us great freedom in processing hardware for flight. Our manifest currently lists more than twenty-five Falcon 1e and Falcon 9 missions, seventeen of those with Dragon spacecraft, so all of our stands will be kept very active.

Merlin Vacuum Engine Expansion Nozzle

We recently fabricated and formed the first flight expansion nozzle for the Merlin Vacuum second stage engine. Made of a thin, high temperature alloy, the large expansion nozzle extends from the regeneratively cooled portion of the engine, and improves its performance in the vacuum of space. Standing 2.7 meters (9 feet) tall and 2.4 m (8 ft) in diameter, it resembles the nozzle used on our Falcon 1's second stage engine, only larger.

The Merlin Vacuum engine expansion nozzle measures 2.7 meters (9 feet) tall,
and most of it has a wall thickness of about 1/3 of a millimeter (1/64 of an inch).
Photo credit: SpaceX.

Interstage

The interstage physically joins the first and second stages, and houses the Merlin Vacuum engine during first stage ascent. The carbon composite cylinder measures 3.6 meters (12 feet) in diameter and nearly 8 m (26 ft) tall.

The top edge of the interstage contains a set of clamping collets that join the first and second stages during liftoff and ascent. After the first stage shuts down, the collets release, and three pneumatic pushers smoothly and forcefully separate the stages, clearing the second stage engine for ignition.

We recently conducted a series of full-scale tests verifying the performance of the separation system under a variety of load conditions. We placed the fully configured interstage in the Falcon 9 structural test stand in Texas, and mounted a large mass on top to simulate the second stage. During testing, the collets release the stage and the pushers force the simulated second stage high into the air. See video below.

The Falcon 9 Interstage (black cylinder at lower center) pushes away the simulated second stage (blue cylinder above).
A series of restraining cables and counterweights capture the load and prevent it from falling downwards.
(Click to play video)

This stage separation system resembles a larger version of the one successfully used on our Falcon 1 vehicle. Note that this system uses no explosives, making it safer to assemble and deploy, and increasing its overall reliability, as we can conduct multiple tests of every flight component, whereas an individual explosive device carries the risk of being fully testable only once — in actual use.

In addition to the stage separation system, the interstage also houses the parachute system that will aide in first stage recovery. Our Cape team has mated the interstage to the first stage and continues to finalize vehicle wiring in preparation for complete vehicle integration.

The Falcon 9 flight interstage in the Cape Canaveral launch site hangar prior to mating with the first stage.
Photo credit: SpaceX.

Dragon Qualification Spacecraft

As mentioned above, the inaugural Falcon 9 flight will loft our Dragon qualification spacecraft into orbit. After completing testing in Texas, the Dragon spacecraft shipped to the Cape in preparation for first flight.

First flight Dragon nosecone (tan, at left), spacecraft (middle) and trunk (right) in process at the SLC-40
launch pad hangar in Florida. Photo credit: SpaceX.

In preparation for flight, the Dragon spacecraft was mated to the trunk (see below), which in future flights will house both unpressurized payloads and the vehicle's solar panels. By flying the Dragon spacecraft configuration, we will obtain valuable data about its performance during the climb to orbit, which will support the following Falcon 9 flight — the first launch under the NASA Commercial Orbital Transportation Services (COTS) program. On that flight, an operational Dragon spacecraft will make several orbit of the Earth, followed by reentry and splashdown in the Pacific Ocean off the coast of California.

Pressurized portion of the Dragon spacecraft, top, mated to the cylindrical unpressurized trunk
section below, with nose cap in foreground. As Dragon has been designed from the start for human
transport, even the cargo and demonstration versions include windows
(circle at top, covered for protection during painting). Photo credit: SpaceX.

Launch Operations – Cape Canaveral SLC-40

As the flight hardware converges on Florida, many significant activities continue around our launch site in preparation for first flight.

Launch Mount

As with our Falcon 1 rocket, the Falcon 9 uses a “hold before launch” system where the launch mount firmly restrains the rocket as it develops full thrust. Once engine performance is verified, the rocket commands the launch mount to set it free.

The Falcon 9's four-part launch mount assembly performs several significant tasks. At rest, it supports the fully fueled Falcon 9, with a mass of over 330,000 kilograms (nearly three-quarters of a million pounds). Next, as the first stage's nine Merlin engines fire and reach full power of nearly 5 MN (over 1 million pounds force), the mounts must hold the vehicle down against the upward thrust.

Finally, upon command, the mounts release the rocket and then move out of the way, giving the nine engines maximum clearance as they lift the vehicle away from Earth.

Months of construction and testing converged into a series of final tests of the launch mount system. The four mount towers were attached to the base of the Transporter / Erector, and their hydraulically powered actuators checked to verify performance.

We then conducted a set of live load tests that simulated the significant downward and upward forces present during the launch sequence. We placed an actual Falcon 9 truss (the structure that joins the nine Merlin engines to the vehicle) into the launch mount, and used a crane and pneumatic cylinders to simulate the forces at liftoff. On command, the launch restraints let the truss fly free. See the video below.

Launch mount system test, with a crane pulling up on a Falcon 9 engine mount truss to simulate the
forces it will experience at liftoff. After releasing the rocket, the mount towers move back to give
maximum clearance to the departing vehicle.
(Click to play video)

Recovery Preparations

Both the Falcon 9 first stage and Dragon spacecraft are designed to be recovered. For this first demonstration flight, the Dragon spacecraft will remain in orbit but our team will attempt recovery of the Falcon 9 first stage and has commenced with recovery testing operations (see photo below).

Flotation testing of a portion of the recovery raft that will aid in returning the Falcon 9 first stage to land after flight.
Photo credit: SpaceX.

Other progress at SLC-40 includes:

• Nearing completion of a new hydraulic system to provide pressurized RP-1 propellant in support of hangar and pad checkout of vehicle Thrust Vector Control (TVC) systems.
• Nearing completion of new gaseous nitrogen system (used for pressurization, line purges, etc.), and a new helium system (used for vehicle pressurization, cooling and engine startup).
• Completion of the liquid nitrogen delivery system and final fill of 4,900 gallons to the site's storage tank.
• Installing new Payload Environmental Control System on the pad to keep future cargo loads comfortable during processing and preparation for launch.
• Functional testing of the new helium fill system. During loading, we chill the Falcon 9's helium storage tanks down to minus 184 degrees C (minus 300 degrees F).

• Multiple test deployments of the Transporter / Erector system (shown above), and the addition of vehicle fill and drain plumbing and umbilical support systems.
• Completed installation of a new dual-redundant, fault tolerant digital information network in support of mission operations and launch pad systems.
• Flow tests verifying the systems that will apply large amounts of water to the launch pad to provide noise and fire suppression during liftoff.

Mission Operations

Radio Tests

Back at our Hawthorne CA headquarters in mid-October we conducted a complete end-to-end test of our Dragon radio communications system with the NASA geosynchronous Tracking and Data Relay Satellite System (TDRSS).

From SpaceX's Hawthorne headquarters, Dragon's 20 watt transmitter and separate receiver antenna (rectangles at left)
communicate with NASA's TDRS 5 satellite on orbit 35,800 km (22,240 mi) above the Earth.
Photo credit: SpaceX.

The SpaceX communications flight hardware, developed with subcontractors Delta Microwave (Low Noise Amplifier), Quasonix (transmitter and receiver), and Haigh-Farr (antennas), emulated a complete Dragon spacecraft comm link, and successfully sent and received data through the TDRSS network. Commands were dispatched from our Hawthorne headquarters command station, to NASA JSC in Houston, across Texas to the TDRSS White Sands Ground Terminal, up to the TDRS 5 Spacecraft in geosynchronous orbit, and back down to the Dragon receiver on the ground in Hawthorne.

The test series demonstrated telemetry and command transmission at a variety of data rates up to 2.1 Mbps, and paves the way for using TDRSS on all fifteen of our Dragon missions for the COTS and Commercial Resupply Services (CRS) programs.

COTS Flight 2 Rehearsals

Also in Hawthorne, we recently completed a very successful joint mission simulation with NASA's Mission Operations Directorate where the team rehearsed the operations that will be conducted during the second COTS flight (the third Falcon 9 launch).

During that mission, dubbed “C2”, a Dragon Spacecraft will approach within 10 kilometers (6 miles) of the International Space Station, and check out navigation, communication and control systems in preparation for actual approach and berthing with the ISS.

Computer illustration showing a Dragon spacecraft approaching the ISS.
Image credit: SpaceX.

These tests help us progress towards the day when SpaceX will begin a series of twelve CRS cargo delivery missions for NASA to support the continued operation of the ISS.

Stay tuned for more Falcon 9 updates in the coming weeks as we head for launch in early 2010.

Dragon/Falcon 9 Update

Wednesday, September 23rd, 2009

We are now only a few months away from having the inaugural Falcon 9 launch vehicle on its launch pad at Cape Canaveral and ready to fly! The actual launch date will depend on weather and how we fit into the overall launch schedule at the Cape, so that is a little harder to predict. Based on prior experience, launch could be anywhere from one to three months after Falcon 9 is integrated at the Cape in November.

This initial test flight will carry our Dragon spacecraft qualification unit (see photos below), providing us with valuable aerodynamic and performance data for the Falcon 9 configuration that will fly on the following COTS and CRS missions for NASA. The second Falcon 9 flight will be the first flight of Dragon under the NASA COTS (Commercial Orbital Transportation Services) program, where we will demonstrate Dragon's orbital maneuvering, communication and reentry capabilities.

The Dragon qualification unit being outfitted with test Draco thruster housings. Depending on mission requirements, Dragon will carry as many as eighteen Draco thrusters per capsule.

Though it will initially be used to transport cargo, the Dragon spacecraft was designed from the beginning to transport crew. Almost all the necessary launch vehicle and spacecraft systems employed in the cargo version of Dragon will also be employed in the crew version of Dragon. As such, Dragon's first cargo missions will provide valuable flight data that will be used in preparation for future crewed flight. This allows for a very aggressive development timeline—approximately 3 years from the time funding is provided to go from cargo to crew.

Test fitting the thermal protection panels that surround the thrusters on the Dragon qualification capsule. The panels must be strong, lightweight, and able to withstand the extreme conditions of space, as well as perform in close proximity to the operating thrusters.

The three year timeframe is driven by development of the launch escape system. This includes 18 months to complete development and qualification of the escape engine, in parallel with structures design, guidance, navigation & control, and supporting subsystems.

Radial bulkheads being installed on the completed pressure vessel for the first COTS Dragon spacecraft. The bays between the bulkheads house Draco thrusters, propellant tanks, parachutes and other vital systems.

Another 12 months will be required to perform various pad and flight abort tests, which are slated to take place at NASA Goddard Space Flight Center's Wallops Flight Facility (Virginia). Under this timeline, the first crew launch would take place 30 months from the receipt of funding, leaving six months of schedule margin to allow for the unexpected.

DragonEye

With the help of NASA's Commercial Crew and Cargo Program Office, the DragonEye Laser Imaging Detection and Ranging (LIDAR) sensor has already undergone flight system trials in preparation for guiding the Dragon spacecraft as it approaches the International Space Station (ISS).

DragonEye launched aboard the Space Shuttle Endeavour on July 15th, 2009 and tested successfully in proximity of the ISS (photos below). DragonEye provides three-dimensional images based on the amount of time it takes for a single laser pulse from the sensor to the reach a target and bounce back, providing range and bearing information from the Dragon spacecraft to the ISS.

DragonEye aboard Space Shuttle Endeavour as seen from the International Space Station. Photo courtesy of NASA.

Images on right captured by the DragonEye LIDAR system during its recent flight aboard Space Shuttle Endeavour (ISS image courtesy NASA).

Image on the right captured by the DragonEye system during its recent flight aboard Space Shuttle Endeavour (ISS Image courtesy NASA).

Dragon Parachute Load Testing

We have also recently completed the parachute load test which was the last part of the Dragon primary structure qualification. Dragon withstood both nominal and off-nominal vertical parachute loads up to 48,000 lbf applied to the main and drogue fittings. The spacecraft is being shipped back to California from our Texas test site where it will continue preparations for its first flight.

Dragon spacecraft undergoing load testing at SpaceX's testing site in McGregor, TX

Dragon with temporary frame installed over it to measure deflections at the ISS docking interface.

First Stage Engines

With twenty-two Falcon 9 flights currently listed on our launch manifest, we're continuing to ramp up all manufacturing lines. The pace of engine production continues to grow, with recent efforts focused on the nine Merlin engines, and one Merlin Vacuum engine for the upcoming inaugural Falcon 9 flight, as well as an identical set of Merlins for the second Falcon 9 flight. Together, the nine Merlin engines produce over 1 million pounds of thrust, and consume over half a million pounds of fuel and oxidizer in just under three minutes as they push the Falcon 9 out of Earth's atmosphere and into orbit.

Nine Merlin engines for the inaugural Falcon 9 flight, ready for integration on to the thrust structure.

Second Stage Engines

At our test facility in McGregor, Texas, testing continues on the Merlin Vacuum engine which will power the Falcon 9 second stage to orbit. Qualification testing was completed last week, and will be followed closely by acceptance testing of the first Merlin Vacuum flight engine for the inaugural launch.

Test firing the Merlin Vacuum development engine on our newest test stand at our Test Site in McGregor, Texas, just outside of Waco. Depending on schedule needs, we can conduct two or more tests per day on this test stand alone.

Click here to view the video tour of our Texas Test site with VP of Propulsion, Tom Mueller. Also, check out the September 2009 issue of Popular Mechanics magazine that profiles Tom and our propulsion systems.

Structures

The nine flight-ready Merlin first stage engines were integrated with the truss structure that evenly distributes their thrust upwards into the first stage tank. Above the truss, the carbon composite skirt (primer green in the photos below) houses the plumbing system that distributes the liquid oxygen (LOX) and RP-1 fuel to the engines.

The entire system was assembled and checked out in our Hawthorne facility, and then shipped to Texas for integration with the first stage propellant tanks, which recently completed proof and leak testing there. The F9 second stage has been shipped to Texas and is being prepped for structural testing which will begin this week, followed closely by stage separation testing.

Weighing in at over 7,700 kg (17,000 lbs), the thrust assembly and nine Merlin engines represents over half the dry mass of the Falcon 9 first stage.

A pair of cranes rotates the entire assembly to horizontal, and then lowers it on to the shipping frame. We then cover everything in a protective layer of shrink-wrap in preparation for travel.

The completed Falcon 9 engine structure departs for Texas, where we'll integrate it with the first stage tank, and conduct a test firing before heading to Cape Canaveral for launch.

Elsewhere in our Hawthorne plant, the launch vehicle for the second Falcon 9 flight is well underway. On the Friction Stir Welding (FSW) machine (above), the first stage tank passed the mid-point with the completion of the fuel tank welding. Additional barrel sections and one more dome will complete the LOX tank. The primary tank structure for the second flight's second stage has already been fabricated and is being processed next to the second stage for the first flight.

Note that the first and second stages use a common architecture such as the same 3.7 meter (12 foot) diameter aluminum-lithium barrels and domes, and we manufacture them utilizing the same systems and tooling. This approach greatly reduces overhead, inventory and production costs, and simultaneously contributes to increased reliability. These are essential aspects of how SpaceX improves reliability and lowers the cost of access to space.

Avionics

The vital electronics and software systems that will operate the Falcon 9 first flight have been integrated and completed final testing, as have our Dragon communications units destined for installation aboard the ISS. SpaceX's COTS UHF Communications Unit is scheduled to fly aboard the Space Shuttle Atlantis on STS-129 this coming November. Read full press release here.

The COTS UHF Communications Unit system, shown here prior to delivery to NASA, will be delivered via the Space Shuttle to the ISS. The system will be installed prior to the approach and berthing on the final COTS mission, and will also see regular use in support of our continuing CRS cargo resupply missions.

Launch Operations

The Cape Canaveral launch site build-up and activation processes continues at Space Launch Complex 40 (SLC-40), our launch pad located a few miles south of the Space Shuttle launch sites on the Florida ‘space coast’. We have completed the new LOX ground handling and storage systems that will supply our Falcon 9 vehicles.

And we are finishing up numerous other systems that support safe and efficient launch operations. Other vital systems now in process include support for the storage and handling of RP-1 fuel, as well as nitrogen, helium, and the water deluge systems that help protect the pad and vehicle from the significant levels of thermal and acoustic energy created during launch.

Conducting the initial filling of the big liquid oxygen storage tank at Space Launch Complex 40.

SpaceX Congratulates Armadillo Aerospace

Monday, September 14th, 2009

SpaceX congratulates John Carmack and the entire Armadillo Aerospace team on the completion of the Level 2 requirements for the X PRIZE 2009 Northrop Grumman Lunar Lander Challenge! SpaceX is a proud supporter of the X PRIZE Foundation, a great example of innovation and inspiration in aerospace.

—Elon—

Falcon 1 | Flight 5

Wednesday, July 15th, 2009

Falcon 1 Successfully Delivers RazakSAT Satellite to Orbit

Hawthorne, CA – July 15, 2009 – Space Exploration Technologies (SpaceX) announces the successful launch of Falcon 1 Flight 5 launch vehicle and the precision placement of Malaysia's RazakSAT into Earth orbit.

“This marks another successful launch by the SpaceX team,” said Elon Musk, CEO and CTO of SpaceX. “We are pleased to announce that Malaysia's RazakSAT, aboard Falcon 1, has achieved the intended orbit.”

Falcon 1, a two-stage, liquid oxygen/rocket-grade kerosene vehicle designed and manufactured by SpaceX, lifted off Monday, July 13, at 8:35 pm (PDT). Lift off occurred from the Reagan Test Site (RTS) on Omelek Island at the U.S. Army Kwajalein Atoll (USAKA) in the Pacific Ocean, approximately 2,500 miles southwest of Hawaii.

RazakSAT was designed and built by Astronautic Technology (M) Sdn Bhd (ATSB), a pioneer and leader in the design and manufacture of satellites in Malaysia.

“Our ground systems were able to pick up communication from RazakSAT on its first pass,” said Norhizam Hamzah, Senior Vice President / Chief Technical Officer, Space Systems Division, ATSB. “The satellite is communicating as expected and our team will continue to monitor the data closely.”

Preliminary data indicates that the RazakSAT, equipped with a high resolution Medium-Sized Aperture Camera (MAC), achieved the intended Near-Equatorial Low Earth Orbit (NEqO) at 685 km altitude and a 9 degree inclination. The payload is expected to provide high resolution images of Malaysia that can be applied to land management, resource development and conservation, forestry and fish migration.

Liftoff of the Falcon 1 RazakSAT mission, from the SpaceX launch site on Omelek Island, US Army Kwajalein Atoll, in the Central Pacific, on 14 July 2009 at 03:35 UTC.

Falcon 9 | Flight 1

Tuesday, June 16th, 2009

First Stage Engines

Engine testing for the inaugural Falcon 9 flight proceeds at a rapid pace with no major problems or concerns. Six of the nine first stage flight engines have completed acceptance testing and all nine flight engines are on schedule to complete acceptance testing by mid July.

Merlin 1C first stage engine firing on the stand at our Texas testing facility.

Second Stage Engine

Our Merlin Vacuum engine (MVac), which powers the Falcon 9 second stage, entered development with a skirt temperature too hot for flight, but we have since tuned down the engine and brought the nozzle temperature within flight specifications. The MVac will complete development by month's end, with qualification testing to follow in July.

Merlin Vacuum (MVac) engine firing on the test stand in Texas. Like the smaller engine on our Falcon 1 second stage, during flight
the MVac engine will also have a large radiatively cooled expansion nozzle to increase its performance in the vacuum of space.

Launch Operations

A key objective of taking Falcon 9 vertical at the Cape earlier this year was to validate ground systems interfaces and operations with the vehicle in its final flight configuration, prior to executing the launch campaign.

First Falcon 9 vehicle at Cape Canaveral's Space Launch Complex 40, former launch site of the Titan IV rocket.

The successful operation allowed us to validate several key interfaces and operations including:

• Mechanical functionality of the erector and its physical fit with the vehicle
• Integration tooling interfaces and function
• Ground system control interfaces
• Environments testing
• Hydraulic systems testing
• Logistics, shipping and equipment handling
• Vehicle integration/mating operations (fairing, stages, erector)
• Vehicle lifting operations
• Launch mount operations

Since that time, our RP-1 system has become operational, the cryogenic Liquid Oxygen handling system is nearing completion, and we have completed construction of our horizontal vehicle integration hangar. The Transporter Erector is getting reassembled into flight configuration and will be back into system level testing in mid-July.

Exterior view of the vehicle integration building, located to the south of the launch pad.

Interior of the vehicle integration building showing the massive overhead crane system, each with a 20 ton lifting capacity.

Our 125,000 gallon liquid oxygen storage sphere (shown below) and supporting pumping station are nearing completion and will undergo cryo shock testing in early July. Next up for completion at the launch site will be auxiliary systems like TEA-TEB handling, spin start support systems, engine purge and launch pad water deluge systems, and Helium chill systems.

Structures

In preparation for the inaugural Falcon 9 flight, our Structures team is hard at work with qualification of the Falcon 9 primary structures. The Falcon 9 first stage with interstage is currently loaded in the structural qualification stand at our Texas facility. Qualification testing is expected to be complete by month's end and we expect to have fully qualified first and second flight stages at SLC-40 by end of summer.

Falcon 9 first stage and interstage (right) on the structural test stand in Texas. To the left is the our
largest test stand, used last November for our successful nine engine mission duration test firing.

The Falcon 9 truss and skirt assembly is complete and loaded in the structural test stand at our headquarters in Hawthorne, California. System checks begin today and proceed into qualification loading later this week. The entire test series will take about 3 weeks to complete.

Pending installation of the transfer tube, our Falcon 9 Flight 1 first stage tank will be completed this week, travel to Texas for proof and leak testing, and then move on to integration. Second stage tank build progress continues with secondary structure installations, and the Falcon 9 fairing build continues as well, with final assembly to start in approximately three to four weeks.

Progress continues on the hardware for Flight 2 of Falcon 9, which will feature our first demonstration flight under the COTS program of the Dragon spacecraft. The friction stir weld process is nearly complete for the second stage tank and the Falcon 9 interstage is in final assembly. In addition, skirt panels are complete through the layup process and ready for assembly integration.

Avionics

Development of the avionics suite for Falcon 9 and Dragon is nearing completion, with key units in final qualification testing and others in production.

Units already in production include:

• Remote Input/Output modules for Merlin engine control
• 10 Mbit/sec network switching nodes for Falcon 9 and Dragon
• High-energy-density Lithium-polymer batteries

SpaceX-developed CUCU (COTS Ultra high frequency Communication Unit) radio transceiver undergoing testing in Avionics'
EMI (electromagnetic interference) test chamber.

In addition, the COTS UHF Communications Unit (CUCU), a dual-redundant digital communications link for Dragon and the ISS, has passed qualification testing and four units are in production. CUCU units on Dragon and the ISS will provide radio communication between the two space vehicles during final approach and berthing of Dragon. The first CUCU production unit is scheduled to be transported by NASA to the ISS aboard the Space Shuttle in late in 2009.

Update

Thursday, May 14th, 2009

It's been an incredibly busy year so far at SpaceX and we continue to move full steam ahead. Of particular note are recent developments with respect to the Dragon spacecraft.

The image below shows the first joining of a full flight fidelity Dragon capsule and trunk section earlier this year on the manufacturing floor at our Hawthorne headquarters.

Standing over 23 feet tall in flight configuration, the stack included the Dragon qualification capsule and first flight trunk section, topped off with the carbon composite nose cap. The cap protects the spacecraft's common berthing mechanism ring, which enables it to join securely to the ISS, so that astronauts can access the interior of the capsule.

The trunk section then travelled to our Texas site where it completed structural testing in preparation for the first Dragon flight under the NASA COTS program, currently scheduled as the second Falcon 9 launch. During that flight, Dragon will make several orbits of the Earth, reenter the atmosphere and splashdown off the coast of Southern California. The gap between the capsule and trunk in the photo above will be filled by our lightweight, high performance PICA-X heat shield panels which will protect the capsule during reentry.

The engineering heat shield shown above has precisely machined test tiles fitted into place in their flight configuration. With 17 Dragon flights presently on our manifest, our PICA-X lab is operating non-stop to meet all our mission needs. SpaceX has come a long way since starting out in 2002 — all the way to Earth orbit. Our team now numbers over 700 and we're still hiring.

Falcon 9 Progress Update

Sunday, January 11th, 2009

Here are more great shots of Falcon 9 vertical on the pad at Space Launch Complex 40 (SLC-40):

Falcon 9 Progress Update

Saturday, January 10th, 2009

Falcon 9 is now vertical at the Cape!

After a very smooth vehicle mating operation yesterday, we began the process of raising Falcon 9 at 12:45pm EST and approximately 30 minutes later, Falcon 9 was vertical at the Cape.

The process of taking Falcon 9 vertical was a critical step in preparation for our first Falcon 9 launch later this year. This accomplishment culminates several months of rapid progress, made possible only through the hard work and dedication of the entire SpaceX team. We will continue to post more photos as available but in the meantime, click the image below for some great time lapse video of the operation:

The SpaceX Falcon 9 rocket standing vertical on its launch pad at Cape Canaveral, FL.
Click any photo for time lapse video of the operation.

Falcon 9 Progress Update

Wednesday, January 7th, 2009

Over the last few days, we kept just ahead of our schedule, rotating the launch deck vertical and mating the strongback. We also installed the main lift cylinders, and raised and lowered the launch mount. Today we took the erector to vertical using the hydraulics system (see below). Getting the erector operational is the final step before taking Falcon 9 vertical.

A view of the erector standing vertical on the launch mount base with the cradle on top.

Elon Musk, CEO and CTO of SpaceX, with Falcon 9 at Cape Canaveral.

Falcon 9 Progress Update

Monday, January 5th, 2009

The New Year got off to a great start for SpaceX with integration of Falcon 9 being completed a day ahead of schedule. Focus then shifted to the launch mount and erector and over the weekend, our team has made incredible progress.

Over the last few days, we flipped the launch mount base and installed it to the launch mount. We also installed the forward cradle and assembled the strongback in preparation for mating to the launch table base. Machining on the forward rail car assemblies was completed, with work on the aft rail car assembly quickly nearing completion, and a significant portion of the hydraulic systems were also installed.

Our next major milestone is rotation of the Launch Deck to vertical in order to initiate mating to the strongback, scheduled for Thursday, January 8th.

Assembling the cradle structure, which mounts at the top of the strongback. The cradle gently grabs the top of the 12 foot diameter Falcon 9 second stage just below the fairing.

The complete cradle attached to the top end of the strongback. A set of electric actuator cylinders operate the gripper. Once Falcon 9 is standing vertical, the cradle opens and the entire strongback tilts away from the rocket for launch.

Our welders finished assembly of the pieces of the launch mount, which we shipped in sections to the Cape. Measuring over 40 feet on a side, it forms the base of the mobile erector that holds the rocket to the pad up until the moment of launch. Total weight of this steel structure — about 97,000 lbs.

After raising the rocket and erector to vertical, the launch mount must be securely attached to the pad itself. A set of linkages (one visible at right) join the launcher to the pad, and a set of large kickback cylinders (center) lock it all in place.

The new Falcon 9 erector rides on four legacy rail cars — two at each end. They roll on the same tracks that once carried Titan rockets to the pad from the old integration building (now demolished) that was located south of the pad.