The Starship Program had its biggest yr so far in 2023, with two full stack flights, massive changes to the launch pad and surrounding systems, extending testing at Masseys, and big changes to the production site.
Shipyard
Firstly of 2023, the Production Site still included the Windbreak, Midbay, and Tent 1 and a couple of. Moreover, the production site still hadn’t been fully connected to the first power grid. Throughout 2023, many changes occurred that can help SpaceX optimize Starship production and maintenance going forward.
This yr SpaceX began constructing the second Mega Bay (Ship Bay) to extend its capability for stacking vehicles. By now, it is almost certain that this latest bay will replace High Bay by way of ship construction. The layout will appear to be what Mega Bay 1 (Booster Bay) now looks like.
Each Mega Bays will feature one turntable within the front corner, which might be used to stack vehicles by rotating the stack along a robotic welder contained in the bay. Then, on the back side of the bays, there are three work platforms that can allow SpaceX to put in engines more easily and do separate work on boosters and ships. Ship 29 is the primary ship to make use of the brand new Ship Bay for engine installation and internal work.
Boca Chica shipyards. (Credit: Jack Beyer for NSF)
SpaceX also upgraded the bridge cranes inside Mega Bay 1 in order that they could lift a booster without engines with just one crane as a substitute of two, which they used to should do. Nevertheless, once fully fitted with engines and shielding, lifting a booster requires each cranes.
With Starfactory, SpaceX made great progress with the Windbreak, Midbay, and Tent 1 and a couple of demolition. By the point crews are completely finished working in the realm, the factory might be around 800,000 square feet since Tent 3 still must be demolished.
Currently, only a number of the layout of Starfactory is understood, reminiscent of the back northeast corner having a press pit, which is for a hydraulic press to stamp and crate parts. The upper section closest to Highway 4 might be used for nosecone construction. Actually, there may be already a nosecone welding jig contained in the factory.
Once Starfactory kicks into full gear together with each the Booster Bay and Ship Bay, SpaceX’s production of ships and boosters will substantially increase. This can allow for more testing and flights so SpaceX can fulfill its biggest contract for Starship, which is the Human Landing System for NASA’s Artemis Moon program.
Nosecone Area of Starfactory. (Credit: Sean Doherty for NSF)
Sanchez Site
Over this past yr, the Sanchez site has undergone many changes. Firstly of the yr, Sanchez still had the propellant production plant and was missing many things now situated there. In the course of the course of the yr, SpaceX used Sanchez to prefabricate the sections of the brand new High Bay after which move them to the brand new bay for the LR-11000 crane to be placed into position.
For the reason that Starfactory expansion required the removal of the Ground Support Equipment (GSE) constructing, SpaceX relocated it to the western corner of Sanchez and upgraded it with insulation in the method. With insulation and air-con, higher work and welding environments were created within the constructing. Alongside the GSE constructing, construction began on two latest white rings and two latest black rings.
The Sanchez Site. (Credit: Jack Beyer for NSF)
These white rings were the work stands for each the Booster Bay (Mega Bay 1) and the brand new Ship Bay (Recent High Bay). The black rings were a brand new transport stand for boosters that are automated in comparison with the old transport stands.
One other significant addition to Sanchez this yr was the ship engine install stand near the Rocket Garden which greatly simplified the installation of engines on ships. Nevertheless, this stand could also be scrapped for the reason that Ship Bay will take over its functions.
SpaceX is now preparing Sanchez to receive all the accomplished tower sections at Roberts Road. These might be for the second Launch Pad at Starbase, and as of at once, it’s unclear when construction will start.
Lastly, the Propellant Production Plant at Sanchez has been dismantled. It’s unknown if SpaceX is giving up and producing its propellant or if it intends to do it at one other location.
Masseys
This yr, SpaceX performed the primary ship cryo-proof test with Ship 25 and later began doing boosters, starting with Booster 10. SpaceX has built two mobile thrust ram stands, one for ship and one for booster. These can transport a ship or booster from the Shipyard to Masseys, perform the vital cryo and structural load tests, after which transport them back.
Recently, tons of groundwork has occurred at Masseys, and SpaceX has even added subcoolers. As of now, it’s unknown exactly what might be built there. Currently, Booster 12 is at Masseys for cryo testing, with this booster likely slated for Flight 5.
The Masseys test site. (Credit: Jack Beyer for NSF)
Launch Site
The Launch Site has modified significantly over the course of 2023, especially with two orbital test flights having been launched from Orbital Pad A at Starbase. Just before the primary flight, SpaceX accomplished the installation of the ultimate pieces of protecting on the Orbital Launch Mount (OLM). This was one in all the ultimate pieces of OLM construction needed before the primary flight.
After the primary flight, there was significant damage to the bottom of the pad, which required a whole redesign of the pad’s foundation and the installation of a brand new water-cooled steel plate flame deflector.
This beefed up the muse to be around 4.5 meters of concrete and steel and pilings happening a minimum of 20 meters, in comparison with the measly 1 meter or so of just fondag concrete used for Flight 1. The opposite big addition was the brand new water flame deflector, which is a steel plate with many small holes used to spray water against the exhaust plume of the booster with a view to protect the bottom and reduce shock to ground equipment.
The launch site. (Credit: Jack Beyer for NSF)
This technique proved its value during Flight 2 when the damage to the pad was minimal. The turnaround between Flight 1 and Booster 9 being mounted to the OLM was three months in comparison with Flight 2 and Booster 10, which was only one month.
SpaceX has also upgraded the Orbital Tank Farm with spots for nine more horizontal tanks. The corporate also finally added two latest pumps and 4 subcoolers on the liquid oxygen side and one pump and one subcooler on the methane side. There have been spots for this expansion ever since they originally built the tank farm. Once all are fully connected and integrated, SpaceX will give you the option to tank and de-tank ships and boosters much faster.
Near the tip of the yr, Suborbital Pad A was demolished. SpaceX hasn’t used this pad for some time, and it’s unclear what SpaceX will use the space for in the longer term.
The demolition of Suborbital Pad A. (Credit: Sean Doherty for NSF)
Flights and testing
SpaceX had a really eventful yr with testing at Starbase, with two full-stack flight tests and lots of testing milestones. First, SpaceX performed the primary full-stack Wet Dress Rehearsal with Booster 7 and Ship 24. This stack would later fly the primary flight. The expectations for the flight weren’t high, and the stack was lost 4 minutes into the flight.
The flight had many issues, however the major issue was a fireplace that had broken out in Booster 7’s engine bay and burned through multiple wire harnesses, which cut off the flight computer’s control of the engines. Each vehicles also had issues with their Flight Termination Systems (FTS).
Booster 7 and Ship 24 in flight throughout the first orbital flight test. (Credit: Max Evans for NSF)
After this flight, SpaceX upgraded the hearth suppression system for Boosters to avoid additional engine bay fires and upgraded the FTS on future Boosters and Ships. With the addition of Hot Staging and other upgrades, Flight 2 performed much better. Booster 9 made it all of the approach to major engine cutoff without losing a single engine, after which Ship 25, using hostaging, separated from the booster perfectly.
Nevertheless, shortly after stage separation, Booster 9 was terminated as a consequence of possible issues with fuel sloshing. Ship 25 nearly made it all of the approach to the second stage engine cutoff; nevertheless, an unknown issue caused the FTS to be activated, and thus the vehicle was destroyed.
Booster 9 and Ship 25 in flight throughout the second orbital flight test. (Credit: Max Evans for NSF)
Together with the 2 flight tests, SpaceX achieved a full 33-engine static fire on Booster 9 and has continued to realize flawless six-engine static fires on ships. Ship 26 and Ship 28 recently performed single-engine static fires with flight-like conditions to simulate a de-orbit burn.
To finish the yr, SpaceX has Ship 28 and Booster 10 out on the pad, with Ship 28 already performing a spin prime and two static fires. Booster 10 also attempted after which accomplished a static fire. Overall, it has been a really successful yr for the Starship program, with many more milestones ahead.
KSC and the longer term
SpaceX has not worked on the Starship pad at LC-39A for several months. The plans for a Florida Starship pad haven’t been canceled, but SpaceX is more focused on flying from Starbase as they determine the whole system. It’s value noting that SpaceX has big plans to expand its Starship capabilities with additional facilities just like SpaceX’s facility at Roberts Road, but it surely is unknown when construction will start.
Launch Complex 39A in Florida. Note the Starship pad to the fitting of the major pad. (Credit: Max Evans for NSF)
For 2024, SpaceX has several full stacks in numerous parts of assembly and testing, and will launch as many as five times. If SpaceX can have flawless or nearly flawless launches, Starship’s cadence can increase dramatically.
