A reusable launch vehicle has parts that can be recovered and reflown, while carrying payloads from the surface to outer space. Rocket stages are the most common launch vehicle parts aimed for reuse. Smaller parts such as rocket engines and boosters can also be reused, though reusable spacecraft may be launched on top of an expendable launch vehicle. Reusable launch vehicles do not need to make these parts for each launch, therefore reducing its launch cost significantly. However, these benefits are diminished by the cost of recovery and refurbishment.
Space Exploration Technologies Corp. commonly referred to as SpaceX, is an American spacecraft manufacturer, launch service provider, defense contractor and satellite communications company headquartered in Hawthorne, California. The company was founded in 2002 by Elon Musk with the goal of reducing space transportation costs and ultimately developing a sustainable colony on Mars. The company currently operates the Falcon 9 and Falcon Heavy rockets along with the Dragon and Starship spacecraft.
A launch escape system (LES) or launch abort system (LAS) is a crew-safety system connected to a space capsule. It is used in the event of a critical emergency to quickly separate the capsule from its launch vehicle in case of an emergency requiring the abort of the launch, such as an impending explosion. The LES is typically controlled by a combination of automatic rocket failure detection, and a manual activation for the crew commander's use. The LES may be used while the launch vehicle is still on the launch pad, or during its ascent. Such systems are usually of three types:
Vertical takeoff, vertical landing (VTVL) is a form of takeoff and landing for rockets. Multiple VTVL craft have flown. The most successful VTVL vehicle was the Apollo Lunar Module which delivered the first humans to the Moon. Building on the decades of development SpaceX's utilised the VTVL concept for its flagship Falcon 9 first stage, which is delivered over two hundred successful powered landings so far.
The SpaceX Draco is a hypergolic liquid rocket engine designed and built by SpaceX for use in their space capsules. Two engine types have been built to date: Draco and SuperDraco.
Falcon Heavy is a partially reusable super heavy-lift launch vehicle that can carry cargo into Earth orbit, and beyond. It is designed, manufactured and launched by American aerospace company SpaceX.
Falcon 9 prototypes were experimental flight test reusable rockets that performed vertical takeoffs and landings. The project was privately funded by SpaceX, with no funds provided by any government until later on. Two prototypes were built, and both were launched from the ground.
SpaceX has privately funded the development of orbital launch systems that can be reused many times, similar to the reusability of aircraft. SpaceX has developed technologies over the last decade to facilitate full and rapid reuse of space launch vehicles. The project's long-term objectives include returning a launch vehicle first stage to the launch site within minutes and to return a second stage to the launch pad following orbital realignment with the launch site and atmospheric reentry in up to 24 hours. SpaceX's long term goal would have been reusability of both stages of their orbital launch vehicle, and the first stage would be designed to allow reuse a few hours after return. Development of reusable second stages for Falcon 9 was later abandoned in favor of the development of Starship, however, SpaceX developed reusable payload fairings for the Falcon 9.
The SpaceX Red Dragon was a 2011–2017 concept for using an uncrewed modified SpaceX Dragon 2 for low-cost Mars lander missions to be launched using Falcon Heavy rockets.
Since the founding of SpaceX in 2002, the company has developed four families of rocket engines — Merlin, Kestrel, Draco and SuperDraco — and is currently developing another rocket engine: Raptor, and after 2020, a new line of methalox thrusters.
As of 2023, SpaceX operates four launch facilities: Cape Canaveral Space Launch Complex 40 (SLC-40), Vandenberg Space Force Base Space Launch Complex 4E (SLC-4E), Kennedy Space Center Launch Complex 39A (LC-39A), and Brownsville South Texas Launch Site (Starbase). Space Launch Complex 40 was damaged in the AMOS-6 accident in September 2016 and repair work was completed by December 2017. SpaceX believes that they can optimize their launch operations, and reduce launch costs, by dividing their launch missions amongst these four launch facilities: LC-39A for NASA launches, SLC-40 for United States Space Force national security launches, SLC-4E for polar launches, and South Texas Launch Site for commercial launches.
The Falcon 9 v1.0 was the first member of the Falcon 9 launch vehicle family, designed and manufactured by SpaceX in Hawthorne, California. Development of the medium-lift launcher began in 2005, and it first flew on June 4, 2010. The Falcon 9 v1.0 then launched four Dragon cargo spacecraft: one on an orbital test flight, then one demonstration and two operational resupply missions to the International Space Station under a Commercial Resupply Services contract with NASA.
Dragon 2 is a class of partially reusable spacecraft developed and manufactured by American aerospace manufacturer SpaceX, primarily for flights to the International Space Station (ISS). SpaceX also launches private missions, such as Inspiration4 and Axiom Space Missions. There are two variants of the Dragon spacecraft: Crew Dragon, a spacecraft capable of ferrying four crewmembers, and Cargo Dragon, a replacement for the original Dragon 1 used to carry freight to and from space. The spacecraft consists of a reusable space capsule and an expendable trunk module. The spacecraft launches atop a Falcon 9 Block 5 rocket and the capsule returns to Earth through splashdown.
SuperDraco is a hypergolic propellant rocket engine designed and built by SpaceX. It is part of the SpaceX Draco family of rocket engines. A redundant array of eight SuperDraco engines provides fault-tolerant propulsion for use as a launch escape system for the SpaceX Dragon 2, a passenger-carrying space capsule.
The Falcon 9 first-stage landing tests were a series of controlled-descent flight tests conducted by SpaceX between 2013 and 2016. Since 2017, the first stage of Falcon 9 missions has been routinely landed if the rocket performance allowed it, and if SpaceX chose to recover the stage.
3D printing began to be used in production versions of spaceflight hardware in early 2014, when SpaceX first flew a flight-critical propulsion system assembly on an operational Falcon 9 flight. A number of other 3D-printed spacecraft assemblies have been ground-tested, including high-temperature, high-pressure rocket engine combustion chambers and the entire mechanical spaceframe and integral propellant tanks for a small satellite.
Starship is an American two-stage super heavy lift launch vehicle under development by aerospace company SpaceX. It is the largest and most powerful rocket ever flown. Starship is intended to be fully reusable, allowing both stages to be recovered after a mission and to be rapidly reused.
SpaceXCrew Dragon In-Flight Abort Test was a successful test of the SpaceX Dragon 2 abort system, conducted on 19 January 2020. It was the final assessment for the Crew Dragon capsule and Falcon 9 launch system before they would be certified to carry humans into space. Booster B1046.4 and an uncrewed capsule C205 were launched from Launch Complex 39A (LC-39A) on a suborbital trajectory, followed by an in-flight abort of the capsule at max Q and supersonic speed. The test was carried out successfully: the capsule pulled itself away from the booster after launch control commanded the abort, and landed safely.
The Commercial Crew Program (CCP) provides commercially operated crew transportation service to and from the International Space Station (ISS) under contract to NASA, conducting crew rotations between the expeditions of the International Space Station program. American space manufacturer SpaceX began providing service in 2020, using the Crew Dragon spacecraft, and NASA plans to add Boeing when its Boeing Starliner spacecraft becomes operational no earlier than 2025. NASA has contracted for six operational missions from Boeing and fourteen from SpaceX, ensuring sufficient support for ISS through 2030.
The Crew Dragon Pad Abort Test was a spacecraft test conducted by SpaceX on 6 May 2015 from the Space Launch Complex 40 (SLC-40) at Cape Canaveral Air Force Station, Florida. As part of the development of NASA's Commercial Crew Program, the test demonstrated the spacecraft's abort system capability, verifying the capsule's eight side-mounted SuperDraco thrusters' capability to quickly power itself away from a failing rocket while it is still on the ground. It was one of the two tests conducted by SpaceX on the abort system of spacecraft, the other one being the Crew Dragon In-Flight Abort Test conducted on 19 January 2020.
