Author Topic: SpaceX Starship : First Flight : Starbase, TX : 20 April 2023 - DISCUSSION  (Read 532624 times)

Offline steveleach

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Costs of an SH and SS:

SH
 Engines -> From $30M to $40M depending on number of engines used (18 vs 23)
 Tank -> from $10M to $15M
 Ancillary hardware etc. -> from $10M to $15M
 Totals
    Min = ~$50M
    Max = ~$70M

SS
 Engines -> from $8M to $10M
 Tank and Fairing -> from $10M to $15M due to complexity of the nose cone shape and extra internal piping and header tanks + tiles attachments
 Ancillary Hardware -> from $15M to $20M The fins complications and the tiles
 Totals
    Min = ~$33M
    Max = ~$45M

Cost of flight hardware for orbital flight
   Min =~$83M
   Max = ~$115M

Or about 6 launches or more in a year without any recoveries for a total cost including all non flight hardware costs such as support GSE, tooling and other ground equipment fees and cryo costs. From a total spending of ~$1B.

I'm not convinced the costs will be anywhere near that high.

Raptors were estimated at around $2m each, BEFORE the spool up in production rate. They are likely well below $1M each by now.

Tanks are only a few $100K in stainless steel, and with the  rate they're churning them out, labor costs can't be more than a few million. 

So my guess is $10M to $15M for SS and $20M to $30M for SH.  With those numbers reducing as they make more of them.


However, the unit cost is almost irrelevent, as the big spend is on the infrastructure to build Raptors, Starships & Super Heavies, then test, launch and land them.  If they spend $1B this year and get one orbital launch, did it cost $1B per launch? That sort of calculation is almost meaningless until they reach steady state, if ever. 

I prefer to look at it this way:

  -  They have invested in and established the capacity (infrastructure, supply chains and people) to build Raptor, Starships and Super Heavies. 
  -  That capacity costs almost as much to sit idle as it does to make units.
  -  Using it builds experince and improves quality, at the minor additinal cost of some raw materials and power.
  -  The designs are not finalized yet, so current builds will not be of use when they eventually reach the operational designs.

So it makes sense to keep churning out prototypes and expending them in ways that inform the operational design.  Or even discard them if they've already moved on.  If they splash a SS and SH on the first orbital ettempt? No big deal, the new & improved versions will be just rolling out of the High Bay.

That said, I expect the SH will try to land on one of the drone ships, 20 km off Boca Chica. There could be a lot to learn by examining an intact, dry, booster, and the landing profile is relatively easy. Probably way too soon for one of the oil rigs to be ready though.

On the other hand, getting another droneship to the SS landing area would be very difficult & dangerous, with pretty low probabilty SS will make it that far intact, and be able to do the flip and stick the landing.
Spot on

Offline oldAtlas_Eguy

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Costs of an SH and SS:

SH
 Engines -> From $30M to $40M depending on number of engines used (18 vs 23)
 Tank -> from $10M to $15M
 Ancillary hardware etc. -> from $10M to $15M
 Totals
    Min = ~$50M
    Max = ~$70M

SS
 Engines -> from $8M to $10M
 Tank and Fairing -> from $10M to $15M due to complexity of the nose cone shape and extra internal piping and header tanks + tiles attachments
 Ancillary Hardware -> from $15M to $20M The fins complications and the tiles
 Totals
    Min = ~$33M
    Max = ~$45M

Cost of flight hardware for orbital flight
   Min =~$83M
   Max = ~$115M

Or about 6 launches or more in a year without any recoveries for a total cost including all non flight hardware costs such as support GSE, tooling and other ground equipment fees and cryo costs. From a total spending of ~$1B.

I'm not convinced the costs will be anywhere near that high.

Raptors were estimated at around $2m each, BEFORE the spool up in production rate. They are likely well below $1M each by now.

Tanks are only a few $100K in stainless steel, and with the  rate they're churning them out, labor costs can't be more than a few million. 

So my guess is $10M to $15M for SS and $20M to $30M for SH.  With those numbers reducing as they make more of them.


However, the unit cost is almost irrelevent, as the big spend is on the infrastructure to build Raptors, Starships & Super Heavies, then test, launch and land them.  If they spend $1B this year and get one orbital launch, did it cost $1B per launch? That sort of calculation is almost meaningless until they reach steady state, if ever. 

I prefer to look at it this way:

  -  They have invested in and established the capacity (infrastructure, supply chains and people) to build Raptor, Starships and Super Heavies. 
  -  That capacity costs almost as much to sit idle as it does to make units.
  -  Using it builds experince and improves quality, at the minor additinal cost of some raw materials and power.
  -  The designs are not finalized yet, so current builds will not be of use when they eventually reach the operational designs.

So it makes sense to keep churning out prototypes and expending them in ways that inform the operational design.  Or even discard them if they've already moved on.  If they splash a SS and SH on the first orbital ettempt? No big deal, the new & improved versions will be just rolling out of the High Bay.

That said, I expect the SH will try to land on one of the drone ships, 20 km off Boca Chica. There could be a lot to learn by examining an intact, dry, booster, and the landing profile is relatively easy. Probably way too soon for one of the oil rigs to be ready though.

On the other hand, getting another droneship to the SS landing area would be very difficult & dangerous, with pretty low probabilty SS will make it that far intact, and be able to do the flip and stick the landing.
Spot on
Which brings up the point on trying to save $3M or even $6M on the 3 RVACS is actually pointless vs the probability of getting a lot of data on the operation of RVACS in their normal operation regimes.

Offline lrk

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That said, I expect the SH will try to land on one of the drone ships, 20 km off Boca Chica. There could be a lot to learn by examining an intact, dry, booster, and the landing profile is relatively easy. Probably way too soon for one of the oil rigs to be ready though.

On the other hand, getting another droneship to the SS landing area would be very difficult & dangerous, with pretty low probabilty SS will make it that far intact, and be able to do the flip and stick the landing.


Landing on a droneship without the catch tower means the booster needs legs.  Which would be more one-off development work that is not applicable long-term. 

Offline Robotbeat

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They still show legs on the diagrams taped to the new parts.

SpaceX sunk a ton of engineering into fairing recovery even though they knew it was only temporary until Starship is online.


I have a theory that Elon intentionally spouts out about their most Ioutlandish ideas and long-term proposals in order to make their near term stuff seem less plausible to their competitors, catching them off guard when they get steamrolled by a very real operational capability. He actually encourages the skepticism and the dismissivism to catch competitors off-guard.
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Offline DistantTemple

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That said, I expect the SH will try to land on one of the drone ships, 20 km off Boca Chica. There could be a lot to learn by examining an intact, dry, booster, and the landing profile is relatively easy. Probably way too soon for one of the oil rigs to be ready though.

On the other hand, getting another droneship to the SS landing area would be very difficult & dangerous, with pretty low probabilty SS will make it that far intact, and be able to do the flip and stick the landing.
Accept it will not be real development work, because they don't need to take care with mass margins, etc, they just need some "knock them up in the field" basic legs. Some heavy girders that fold down like-but-unlike the F9 composite legs would do.

Landing on a droneship without the catch tower means the booster needs legs.  Which would be more one-off development work that is not applicable long-term.
« Last Edit: 05/18/2021 11:36 pm by DistantTemple »
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Offline aero

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Just wondering, how many launches of the SH/SS stack do you suppose they might want to make before the catch tower is completed? Will they launch a stack from the cape? The answer kind of defines "long term."
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Offline su27k

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Just wondering, how many launches of the SH/SS stack do you suppose they might want to make before the catch tower is completed?

From the most recent NSF Starship article:

Quote
While the SN20 and BN3 combo will be first in line for orbital flight, it’s expected that the subsequent boosters and ships will pair up accordingly, SN21 with BN4, SN22 with BN5, and SN23 with BN6. In addition, it’s understood that a major design upgrade is set to come with the SN24/BN7 pair.

From this it looks like they're planning at least 4 expendable SH launches, and the major upgrade by SN24/BN7 could very well be a SH that is catchable by the tower.

Offline su27k

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User softwaresaur on reddit discovered a FCC filing for a Starlink Ku band ground station with a single off the shelf Cobham MK3 antenna in Honolulu, Hawaii, this is different from regular Starlink ground stations which have 8 Ka band SpaceX antennas. Speculation is this ground station will be used to communicate with Starship during its flight towards splashdown site near Kauai.

Offline sebk

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Adding to the RVacs or not on SN-20 discussion:

This may depend on the readiness state of RVacs. If SpaceX deems RVacs are too likely to jeopardize the mission they may skip them. It seems their primary goal is trying EDL -- this is the hardest next step for them, after all. RVac testing is a "drive by" secondary goal. If the engines are deemed good enough then sure, include them and have a good validation test on ascent. But if they assign too much probability of them failing and causing on-ascent RUD they would fly without them.

Offline Mike_1179

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User softwaresaur on reddit discovered a FCC filing for a Starlink Ku band ground station with a single off the shelf Cobham MK3 antenna in Honolulu, Hawaii, this is different from regular Starlink ground stations which have 8 Ka band SpaceX antennas. Speculation is this ground station will be used to communicate with Starship during its flight towards splashdown site near Kauai.

The Starlink antenna on Starship is located on the leeward (dorsal) side presumably so it can talk upward to the Starlink constellation during entry. When would this ground station be in view of that antenna on Starship?

If not, then this Honolulu station would just be for talking to the constellation as it relays data down from Starship. So, then why not use a regular ground station, why a custom?

Offline rsdavis9

They still show legs on the diagrams taped to the new parts.

SpaceX sunk a ton of engineering into fairing recovery even though they knew it was only temporary until Starship is online.


I have a theory that Elon intentionally spouts out about their most Ioutlandish ideas and long-term proposals in order to make their near term stuff seem less plausible to their competitors, catching them off guard when they get steamrolled by a very real operational capability. He actually encourages the skepticism and the dismissivism to catch competitors off-guard.

So f9 is 20t.
SH is 230t? 180t?
Any chance that the existing f9 legs could be used?
6 of them?
8 of them?
Are the current f9 legs over designed somewhat and can actually take a larger load?
How quick could they make an upgrade of the f9 legs for the larger loads?

EDIT: onespeed estimates 10.
https://forum.nasaspaceflight.com/index.php?topic=47179.msg2240197#msg2240197
« Last Edit: 05/19/2021 02:21 pm by rsdavis9 »
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Offline TripD

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Everyone is missing the most important question.


What's the weather like in Boca Chica in July?  8)

Offline su27k

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User softwaresaur on reddit discovered a FCC filing for a Starlink Ku band ground station with a single off the shelf Cobham MK3 antenna in Honolulu, Hawaii, this is different from regular Starlink ground stations which have 8 Ka band SpaceX antennas. Speculation is this ground station will be used to communicate with Starship during its flight towards splashdown site near Kauai.

The Starlink antenna on Starship is located on the leeward (dorsal) side presumably so it can talk upward to the Starlink constellation during entry. When would this ground station be in view of that antenna on Starship?

If not, then this Honolulu station would just be for talking to the constellation as it relays data down from Starship. So, then why not use a regular ground station, why a custom?

Pretty sure the ground station would just talk to the constellation which will relay the data from Starship. Not sure why they wouldn't use a regular ground station, maybe they're not ready to expand service to Hawaii yet? I don't know what is the fiber connection bandwidth between Hawaii and US mainland, it's possible the bandwidth is not sufficient to support a regular ground station offering commercial service, but it is sufficient for relaying some data from Starship test. They may be waiting for laser link to be operational before expanding Starlink service to Hawaii.
« Last Edit: 05/19/2021 02:38 pm by su27k »

Offline Robotbeat

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They still show legs on the diagrams taped to the new parts.

SpaceX sunk a ton of engineering into fairing recovery even though they knew it was only temporary until Starship is online.


I have a theory that Elon intentionally spouts out about their most Ioutlandish ideas and long-term proposals in order to make their near term stuff seem less plausible to their competitors, catching them off guard when they get steamrolled by a very real operational capability. He actually encourages the skepticism and the dismissivism to catch competitors off-guard.

So f9 is 20t.
SH is 230t? 180t?
Any chance that the existing f9 legs could be used?
6 of them?
8 of them?
Are the current f9 legs over designed somewhat and can actually take a larger load?
How quick could they make an upgrade of the f9 legs for the larger loads?

EDIT: onespeed estimates 10.
https://forum.nasaspaceflight.com/index.php?topic=47179.msg2240197#msg2240197
There are pictures of what they might look like. Probably, if SH has legs, they'll just be permanently welded ones like in the old renderings (but maybe simplified?).
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To the maximum extent practicable, the Federal Government shall plan missions to accommodate the space transportation services capabilities of United States commercial providers. US law http://goo.gl/YZYNt0

Offline aero

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Elon does like to save money. Maybe if BN-3 sets down gently on the water he will tally up the cost of the engines then think hard on a way to save them in future flights. Legs come to mind. For a prototype launch with a light cargo, the legs can be relatively massive ...

I wonder if there will be any test flights after the booster landing tower is completed?
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Offline oldAtlas_Eguy

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User softwaresaur on reddit discovered a FCC filing for a Starlink Ku band ground station with a single off the shelf Cobham MK3 antenna in Honolulu, Hawaii, this is different from regular Starlink ground stations which have 8 Ka band SpaceX antennas. Speculation is this ground station will be used to communicate with Starship during its flight towards splashdown site near Kauai.

The Starlink antenna on Starship is located on the leeward (dorsal) side presumably so it can talk upward to the Starlink constellation during entry. When would this ground station be in view of that antenna on Starship?

If not, then this Honolulu station would just be for talking to the constellation as it relays data down from Starship. So, then why not use a regular ground station, why a custom?

Pretty sure the ground station would just talk to the constellation which will relay the data from Starship. Not sure why they wouldn't use a regular ground station, maybe they're not ready to expand service to Hawaii yet? I don't know what is the fiber connection bandwidth between Hawaii and US mainland, it's possible the bandwidth is not sufficient to support a regular ground station offering commercial service, but it is sufficient for relaying some data from Starship test. They may be waiting for laser link to be operational before expanding Starlink service to Hawaii.
It is a possibility this is what is sometimes called a suedosat. It would point at the location of final landing maneuvers which would take the vehicle out of connection to sats. If the location is on top of one of Hawaii's tall mountains such as next to an existing observatory where Internet broadband data speeds are available then it is a clincher.
ADDED: I stand corrected. It is at the exhibition hall in downtown Honolulu. It is possible that it is a setup for transmission of the Starship flight presentations to a crowd of reporters direct through the Starlink network point to point from wherever SpaceX Starship mission control is being done at. It would be a twofer. It demonstrates Starlink and shows off Starship at the same time.
« Last Edit: 05/19/2021 07:04 pm by oldAtlas_Eguy »

Offline Kiwi53

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I don't know what is the fiber connection bandwidth between Hawaii and US mainland, it's possible the bandwidth is not sufficient to support a regular ground station offering commercial service, but it is sufficient for relaying some data from Starship test. They may be waiting for laser link to be operational before expanding Starlink service to Hawaii.

Fibre/er capacity between Hawai'i & California is immense.
Apart from any US-specific cables, the 'Southern Cross' cable that connects Australia, New Zealand and the USA is a 'figure 8' with the cross-over in Hawai'i. It has a design capacity of >20Tb/sec and a lit capacity of 10Tb/sec.
I'm sure Verizon, a part owner, would rent SpaceX whatever capacity they needed.
https://en.wikipedia.org/wiki/Southern_Cross_Cable

Offline AstroStrike

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I would be very interested to see a map of the full orbital flight path and what countries it would fly over. I tried working it out but my orbital mechanics isn't very good! Does anyone have any quick mock ups?

Offline Yggdrasill

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From this it looks like they're planning at least 4 expendable SH launches, and the major upgrade by SN24/BN7 could very well be a SH that is catchable by the tower.
Sticking with one design for the first four orbital flights does not mean expending everything. It could go something like this:

BN3/SN20: SH east coast splashdown and Starship west coast splashdown.
BN4/SN21: SH ASDS landing and Starship west coast splashdown.
BN5/SN22: SH RTLS landing and Starship east coast ASDS landing.
BN6/SN23: SH RTLS landing and Starship Boca Chica landing.

The question is really how fast SpaceX can get approval for landings with a greater damage potential. (And how well the SH/Starship performs, of course.)
« Last Edit: 05/20/2021 07:04 am by Yggdrasill »

Offline RotoSequence

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Sticking with one design for the first four orbital flights does not mean expending everything.

The Starship program doesn't have a history of completely changing their flight plans until a given build series accomplishes its test objectives, so I'd be surprised if they started making dramatic changes in testing before they start launching payloads.
« Last Edit: 05/20/2021 07:14 am by RotoSequence »

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