SpaceX has officially received the list of actions that it needs to take to ensure that the Starship rocket complies with FAA regulations. SpaceX's April Starship test launch was quite a spectacle. While it saw the world's biggest rocket successfully soar to the sky after clearing the pad, the remainder of the flight provided metal-fueled fireworks that saw the rocket flip multiple times in mid-air before exploding. The FAA released today's press release explaining the work it has been doing with SpaceX after the April test attempt. Simultaneously, SpaceX also released a press release clearing up some uncertainties about a couple of failures during the April launch.
SpaceX Confirms Flight Termination System Delay, Provides Reasons For Starship Test Flight Malfunction
Apart from the mid-air gymnastics, which were quite a sight on their own, the April test also saw multiple fires in Starship's engine bay. Several of the rocket's engines also fizzled out during the flight. SpaceX's latest statement shares that the engine problems ultimately led to an unsuccessful second-stage separation and orbital test flight.
According to SpaceX, propellant leaks at the rocket's tail (aft) end led to multiple fires inside it. These affected the primary Starship computer, which eventually failed. This failure was the primary reason behind the rocket's explosion since it made SpaceX unable to communicate with the engines, leaving SpaceX unable to communicate with the 394-foot-tall rocket.
Interestingly, SpaceX also mentions that it upgraded the rocket's thrust vector control (TVC) system. This system is responsible for moving the engines, allowing SapceX to control the rocket. SpaceX's details about the upgrade start out by 'clarifying' that the upgrade is "unrelated to any issues observed during the first flight test," as it explains that the new TVC system uses fully electric motors with fewer points of failure and greater energy efficiency.
In the immediate aftermath of the Starship test flight, there was speculation that the rocket's TVC system had failed due to impact from launch pad debris. The company also shared that the hot stage ring added to the top of the first stage rocket is also unrelated to any flight mishap. This explanation falls in line with the primary reason for the test failure which was a loss of communication with the rocket's engines.
Soon after the April test, SpaceX chief Mr. Elon Musk took to X (formerly Twitter) and explained that his firm would upgrade the Raptor engine's hot gas manifold that was suffering from leaks. He outlined that a "sort of methane rich hot gas [was] leaking through the bolt holes of the fuel manifold," and analyzing this together with the language of today's release indicates that perhaps these leaks were the main reason for the fires that damaged Starship's computer.
For its part, the FAA has completed its review of SpaceX's investigation report, the agency confirmed in a press release earlier today. It also shared an email sent to SpaceX's director of Starship reliability, Shana Diez, where it commented:
The final mishap investigation report cited a total of sixty-three (63) corrective actions for SpaceX to implement. These included actions to address redesigns of vehicle hardware to prevent leaks and fires, redesign of the launch pad to increase its robustness, incorporation of additional reviews in the design process, additional analysis and testing of safety critical systems and components including the Autonomous Flight Safety System (AFSS), and the application of additional change control practices.
Astute readers will note that SpaceX's press release confirms that the firm has already made some of these changes, which reduces the time for the next stage in the regulatory approval process for the second Starship test flight. SpaceX's Starship launch license gave the go-ahead for a single launch. For another launch, the firm must "demonstrate compliance" with laws "by evidencing the implementation of corrective actions adopted in response to its April 20, 2023 mishap."
The FAA concludes its correspondence by stating that SpaceX will have to make all 63 changes that threaten human or environmental safety if it wants to regain compliance for launch. Footage from SpaceX's Boca Chica site has shown some changes to the self-destruct system, but the progress of upgrades on this crucial rocket component is uncertain.
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