In an unexpected yet remarkable achievement, SpaceX has successfully executed a complex maneuver that many deemed highly unlikely. The company achieved this feat during the fifth integrated test flight of Starship, which took off on October 13 from SpaceX’s facility in Boca Chica, Texas. The mission involved the Super Heavy booster returning to its launch tower and being caught by large mechanical arms, whimsically named “chopsticks.”
The intricacies of this task were daunting, reminiscent of SpaceX’s early, often unsuccessful, attempts to land Falcon 9 boosters. Yet, despite widespread skepticism, there was a sense of quiet confidence within SpaceX. Just days before the launch, Bill Gerstenmaier, SpaceX’s vice president of build and flight reliability, expressed optimism. He pointed out that during a previous test in June, the Super Heavy booster had managed to “land” with extraordinary precision in the Gulf of Mexico. This feat bolstered SpaceX’s belief that they could indeed achieve a successful catch at the launch tower.
On the day of the test, this confidence proved well-founded. The Super Heavy booster executed a flawless return to the launch tower shortly after liftoff. The chopsticks mechanism engaged seamlessly, securely holding the booster in place. This accomplishment marks a significant milestone in SpaceX’s ambitious plan to make Starship rapidly reusable. The company envisions a future where Super Heavy boosters return to the launch pad, promptly receive a new Starship upper stage, and are prepared for subsequent launches in a matter of days or even hours.
The successful catch is not merely a triumph for SpaceX’s specific Starship program but also symbolizes a broader shift in the aerospace industry towards reusable launch vehicles. SpaceX has already demonstrated this capability with the Falcon 9 boosters, which have been reused over 20 times. However, Starship is set to redefine the possibilities of reusability in space travel. Recognizing SpaceX’s lead in this domain, other companies and nations are increasingly acknowledging the necessity of embracing reusability to remain competitive.
### The Imperative of Reusability
Across various recent industry conferences, from Milan to Mountain View, there’s a growing consensus that the future of space access lies in reusable launch systems. S. Somanath, chairman of the Indian Space Research Organisation (ISRO), emphasized this during the International Astronautical Congress in Milan, stating, “Reusability is mandatory for launchers.” He articulated that reducing launch costs is essential to expanding space programs globally, making space more accessible and affordable.
In alignment with this vision, the Indian government has greenlit ISRO’s Next Generation Launch Vehicle (NGLV) project. This endeavor aims to develop a reusable rocket capable of transporting up to 30 tons to low Earth orbit, tripling the capacity of India’s existing LVM3 rocket, albeit at only 50% more cost. The cost-efficiency is expected to stem from a reusable booster with an engine capable of throttling, powered by liquid oxygen and methane to facilitate controlled landings.
This sentiment was echoed at the Satellite Innovation conference in Mountain View, where Adam Spice, Rocket Lab’s chief financial officer, stated, “If you don’t have a reusable launch vehicle, I don’t think you have a future as a launch company.” Rocket Lab has been experimenting with reusability on its Electron rocket, though it has yet to re-fly a complete booster. Nevertheless, the experience gained is invaluable for their Neutron rocket, which is expected to debut in 2025 and will heavily rely on reusability.
### Global Pursuit of Reusable Technology
Other industry players are making strides toward reusability, following the trail blazed by SpaceX. Blue Origin is preparing for the inaugural launch of its New Glenn rocket, with ambitions to land the first stage on an ocean-going platform. The company’s CEO, Dave Limp, expressed confidence in their ability to achieve this challenging feat on the first attempt.
Stoke Space is advancing the concept of reusability by developing a two-stage vehicle where both stages are designed for recovery and reuse, echoing SpaceX’s ultimate goal for Starship. This approach could significantly reduce manufacturing demands and shift the focus to operational efficiencies, as described by Devon Papandrew, Stoke’s vice president of business development.
### Europe’s Reusability Ambitions
In Europe, responses to SpaceX’s advancements have been mixed. Josef Aschbacher, director general of the European Space Agency, acknowledged the technical prowess demonstrated by SpaceX and highlighted the need for Europe to reassess its position in the global space landscape. Some European entities, like Rocket Factory Augsburg, have openly criticized the region’s lag in reusable technology development. Nevertheless, promising initiatives are emerging, such as MaiaSpace’s efforts to develop a small launch vehicle with a reusable booster.
Spain’s PLD Space is another European company making headway in reusability. Celebrating the first anniversary of its Miura 1 suborbital launch, PLD Space unveiled a decade-long strategy involving its Miura 5 vehicle, which aims to gradually integrate reusability features. Initially contemplating parachute landings, the company now plans to implement propulsive landings akin to SpaceX’s approach.
### ULA’s Alternative Approach
While the industry generally leans toward full or partial booster recovery, United Launch Alliance (ULA) is pursuing a different reusability strategy with its Vulcan rocket. Rather than recovering the entire booster, ULA aims to reuse only the engine section using its Sensible Modular Autonomous Return Technology (SMART). This approach focuses on retrieving the most valuable components, arguing that the Vulcan booster’s high-energy design makes full recovery impractical.
### Reusability: A Path to Sustainable Space Access
Despite the evident push towards reusability, some industry voices remain cautious. Giulio Ranzo, CEO of Avio, maintains that reusability is not a universal necessity for survival, especially in regions lacking a substantial customer base. However, Avio is exploring technologies that could support future reusable vehicles.
Rocket Lab’s experience highlights the challenges of aligning reusability with market demand. The company initially pursued reusability to enhance Electron’s launch frequency but has since adjusted its focus to their upcoming Neutron rocket due to lower-than-expected demand.
Even SpaceX occasionally prioritizes mission requirements over reusability, as demonstrated during the launch of NASA’s Europa Clipper mission, where the Falcon Heavy rocket’s booster cores were expended to fulfill the mission’s demanding payload requirements.
In conclusion, the shift towards reusability is reshaping the aerospace industry, driven by the need to lower costs and increase access to space. SpaceX’s recent success with the Super Heavy booster marks a pivotal step in this movement, setting a precedent for rapid and frequent reuse of launch vehicles. As more companies and countries join this pursuit, the future of space exploration promises to be more accessible, sustainable, and innovative.
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