SpaceX Recovers Booster but Loses Starship in Ambitious Test Flight

SpaceX achieved a significant milestone with the recovery of its Super Heavy booster during its seventh Starship test flight. However, the mission also faced challenges, as the upper stage, Ship 33, failed during ascent. The test shows both the risks and progress in developing reusable spaceflight technology. Reusable spaceflight technology refers to spacecraft that can be used multiple times for missions. This means the same spaceship can go to space, come back, and then go again. Developing this technology is a big step forward. But there are also challenges and dangers involved.

Summary

• Super Heavy Booster Recovery: SpaceX successfully recovered the Super Heavy booster using “Mechazilla,” marking the second time the chopstick-style arms caught the booster above ground.
• Upper Stage Failure: The upper stage, Ship 33, experienced a “rapid unscheduled disassembly” (RUD) during ascent due to an oxygen/fuel leak near the engine firewall, according to Elon Musk’s post.
• Improved Design Features: Ship 33 featured upgraded avionics, propulsion systems, forward control flaps, and next-generation heat shield tiles. A backup layer of heat-resistant material was also stress-tested.
• Impact of Failure: The FAA briefly slowed or diverted aircraft to avoid falling debris from the incident, per official reports.
• Test Objectives: Ship 33 was designed to deploy 10 Starlink simulators to test deployment procedures for future satellite launches.
• Starship System Overview: Starship is the world’s most powerful launch vehicle, with 33 Raptor engines producing 16.7 million pounds of thrust. The system is fully reusable and stands 403 feet tall.
• SpaceX’s Ambitions: Future missions aim to achieve full reuse of both Super Heavy and Ship, as well as interplanetary exploration, including uncrewed Mars missions by 2026 and crewed missions within four years.
• Historical Context: The test showcased advances over previous missions, such as last October’s first successful booster catch using the “Mechazilla” system.
• Applications for NASA: A customized Starship version is planned for NASA’s Artemis III lunar mission, expected by mid-2027.
• Future Upgrades: Musk outlined plans to double-check for leaks, add fire suppression systems, and expand venting capacity for subsequent launches.

Introduction

SpaceX’s seventh test flight of its massive Starship system had both successes and failures. The company made progress in reusability by successfully recovering the Super Heavy booster. However, the upper part of the rocket, called Ship 33, experienced a major problem while going up. This issue ended the test early. Even with this setback, SpaceX is dedicated to improving the system. They want to achieve big goals, like missions to Mars and further.

Starship and Super Heavy: Engineering Marvels

The Starship launch system consists of two main components: the Super Heavy booster and the Starship upper stage. Together, they create the most powerful rocket system ever built, capable of producing 16.7 million pounds of thrust.

• Super Heavy Booster: Equipped with 33 methane-fueled Raptor engines, the booster provides the initial thrust required for liftoff. Its reusability is a major focus, as demonstrated by the successful catch during this mission.
• Starship Upper Stage: This stage is designed for tasks like satellite deployment, crewed lunar landings, and eventually Mars exploration. Ship 33, used in this test, included several design upgrades, such as next-generation heat shield tiles and improved avionics.

Learn more about Starship’s technical specifications here.

What Went Right: Super Heavy’s Recovery

For only the second time in SpaceX’s testing history, the Super Heavy booster was successfully caught by the Mechazilla system. This innovative approach uses mechanical arms on the launch tower to secure the returning booster mid-air.

This achievement builds on the first successful catch in October 2024, further validating SpaceX’s plans for fully reusable rocket systems.

Watch the October 2024 booster catch here.

What Went Wrong: Ship 33’s RUD

Unfortunately, the upper stage, Ship 33, failed to complete its mission. According to SpaceX, the failure occurred due to an oxygen/fuel leak near the engine firewall. This resulted in a “rapid unscheduled disassembly” (RUD) during ascent.

Elon Musk explained the failure in a post on X:

“Preliminary indications suggest a leak in the cavity above the engine firewall led to pressure buildup. Future improvements will include fire suppression and enhanced venting systems.”

The debris from Ship 33’s breakup created temporary disruptions to commercial air traffic, as noted by the FAA’s report.

Just saw the most insane #spacedebris #meteorshower right now in Turks and Caicos ⁦@elonmusk⁩ what is it?? pic.twitter.com/a7f4MbEB8Q

— Dean Olson (@deankolson87) January 16, 2025

A view of Starship as seen from an airplane 😳pic.twitter.com/MfmavSCKUa

— Jenny Hautmann (@JennyHPhoto) January 17, 2025

Aiming for the Stars: SpaceX’s Vision

• Satellite Deployment: SpaceX plans to use Starship for large-scale launches of its Starlink satellites to low Earth orbit (LEO). This test included mock Starlink payloads.
• NASA Collaboration: A custom Starship variant is set to land astronauts on the Moon as part of NASA’s Artemis III mission, scheduled for no earlier than mid-2027.
• Mars Missions: SpaceX envisions sending uncrewed Starships to Mars by 2026, followed by crewed missions four years later.

Read about SpaceX’s Mars plans in Elon Musk’s post.

Technical Challenges and Next Steps

Ship 33’s failure underscores the complexity of developing a fully reusable rocket system. To address the issues, SpaceX plans to:

• Improve Leak Detection: Enhanced quality control processes to detect potential leaks before launch.
• Add Fire Suppression Systems: New measures to extinguish potential fires in critical areas.
• Expand Venting Capacity: Increased venting to manage pressure buildup during ascent.

These upgrades aim to support SpaceX’s goal of monthly Starship launches in the near future.

Follow SpaceX’s updates on future launches here.

Comparison: Starship vs. Competitors

The Starship system stands apart from other launch systems in terms of thrust and reusability.

Feature	SpaceX Starship	NASA’s SLS	Saturn V
Liftoff Thrust	16.7 million pounds	8.8 million pounds	7.5 million pounds
Reusability	Fully reusable	None	None
Height	403 feet	322 feet	363 feet

Explore more about Starship’s capabilities here.

Facts About Starship

• Largest Rocket Ever Built: At 403 feet tall, Starship surpasses both the Saturn V and NASA’s SLS in size.
• Twice the Thrust: Starship generates nearly twice the thrust of the Apollo-era Saturn V rocket.
• Fully Reusable: Unlike NASA’s SLS, Starship is designed to be fully reusable, significantly reducing launch costs.

Watch Starship in action during its latest test flight.

Challenges Ahead: FAA Oversight and Safety

Following the RUD incident, the FAA has pledged to investigate the root cause and ensure compliance with safety protocols.

The FAA’s statement read:

“The FAA briefly slowed and diverted aircraft around the area where space vehicle debris was falling. Normal operations have resumed.”

This highlights the growing need for safety measures in the burgeoning field of commercial space travel.

Learn about FAA’s role in spaceflight safety here.

Looking Ahead: Ambitions for Mars and Beyond

SpaceX’s ultimate vision is to establish a self-sustaining city on Mars within the next two decades. Musk believes this requires exponential growth in flight frequency and reliability.

A timeline for Mars missions includes:

• 2026: First uncrewed Mars landings.
• 2028: Initial crewed missions if uncrewed tests are successful.
• 2040s: Self-sustaining city established.

See Elon Musk’s vision for humanity on Mars here.

SpaceX’s seventh Starship test exemplifies both the risks and rewards of pushing the boundaries of space exploration. While the loss of Ship 33 underscores the challenges ahead, the successful recovery of the Super Heavy booster demonstrates SpaceX’s ongoing commitment to full reusability.

As SpaceX continues to refine its technology, the possibilities for humanity’s interplanetary future remain boundless.

References

1. Elon Musk’s update on X
2. SpaceX’s Starship Overview
3. Cosmic Log Article on Booster Recovery
4. Reuters Article on the Test Flight
5. Watch the Test Flight on YouTube

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