Author Topic: Will Mars-bound Starships actually be reused?  (Read 130504 times)

Offline Robotbeat

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Re: Will Mars-bound Starships actually be reused?
« Reply #80 on: 08/01/2023 03:30 am »
I actually don’t think Mars will be power starved.

We know how to make almost nothing on Mars.

The only things we've made on Mars are electricity from solar and nuclear (radioisotope). AND oxygen (and carbon monoxide fuel, I suppose) from MOXIE.

Propellant, and the power to produce it, is pretty much the only thing we know how to make on Mars right now with high certainty.

And solar panels can be pretty lightweight and cheap. Cells themselves are ~600-1200W/kg, if shipped with a glass covering maybe 500-600W/kg. The frames can be produced on Mars (very simple, could be 3D printed, injection-molded, extruded, even be made of brick or just smooth sand) Or complete solar panels could be made bringing the specific power to 150W/kg. (That's EARTH sunshine levels, though... Mars would be more like 67W/kg completed, 270W/kg for encapsulated cells.)

So the transport cost per watt to Mars may not be too bad. Supposing Launch from Earth is $100/kg for bulk, slow cargo, the cost per watt of the solar panel may only be about $0.50-$2/Watt (at Mars) including the cost of the cells and panels themselves (you can technically get cheap panels for 15 cents per kWh right now... 30 cents at Mars' light levels). With a lifetime of 25 years, and a capacity factor of 20-25%, that's 1-5 cents per kWh, maybe double that depending on cost of capital. 1-10 cents per kWh.

Launching a Starship back to Earth (orbit?) requires what, maybe 5.5km/s from the equator? So given a Raptor Isp of 3.7km/s, that's e^(5.5/3.7) = 4.42 of a mass ratio. So each kg sent back (including the ship dry mass) takes 3.42kg of propellant. Assuming a 3.8 O:F ratio, that's 0.7kg of methane on Mars for every kg of dry mass (including payload) sent back  to Earth orbit. That's really not that bad. 1kg of methane has an embodied energy of 55MJ/kg, or 100MJ/kg if you are including inefficiencies (and energy needed to harvest CO2 and H2O), and you're at 70MJ per kg of dry mass/payload to Earth orbit. 70MJ is about 20kWh.

So the energy cost of that propellant might only be about $0.20-$2/kg-of-drymass-and-payload-back-to-Earth. There's additional capital cost in the electrolysis and stuff, and I intentionally didn't include the cost of the string inverter, etc, because the electrolysis cell can actually be designed to work directly with the solar panels without extra power electronics (Terraform Industries is doing this). So if we say the propellant equipment capital cost (plus install cost for solar) is equal to the energy capital cost, Then we might be only looking at around $0.40-$4/kg to send stuff back to Earth orbit, which not only is much cheaper than the optimistically low $100/kg cost of a Starship, but could be cheaper even than launching from Earth itself to LEO (plus you could stop at HEO, which is even more expensive than LEO).

...in fact, the ships might not want to dead-head at all. You MIGHT want to send fully-fueled Starships to LEO (or, more efficiently, have them stop by HEO first to refuel a tanker there before going down to LEO) where they could pick up about 100 passengers each from 500 passenger short-duration-LEO-optimized Starships (meaning the number of passengers-to-Mars-per-Earth-Starship-Launch could go from the baseline 20 to like up to 500, with the Mars-transfer-Starships being serviced on Mars herself, giving the Mars City something pretty valuable to do).

So again, I don't think we should assume Mars will be so energy-starved that they can't send ships back. The cost of refueling the Starships to send them back empty may easily be worth it and perhaps by an order of magnitude...
« Last Edit: 08/01/2023 04:13 am by Robotbeat »
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Offline Robotbeat

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Re: Will Mars-bound Starships actually be reused?
« Reply #81 on: 08/01/2023 05:49 am »
Let's take a simple example. Let's say I have 50W_Mars/kg solar panels and 50W/kg of electrolysis and sabatier equipment. And let's say I have 200 tonnes of payload to the surface of Mars per cargo ship, half solar and half propellant production, whose dry mass will be 100 tonnes. That means I get 5MW of solar per trip. With a 20% capacity factor, that's about 1MW on average.

To send 100 tonnes dry mass back costs 70 tonnes of methane. With 100MJ/kg to make methane and 1MW, that means I can produce enough propellant to send that ship back in just 81 days out of the 26 months it takes to do a synod.

Mars has no reason to be energy-starved.
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Offline meekGee

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Re: Will Mars-bound Starships actually be reused?
« Reply #82 on: 08/01/2023 06:17 am »


Let's take a simple example. Let's say I have 50W_Mars/kg solar panels and 50W/kg of electrolysis and sabatier equipment. And let's say I have 200 tonnes of payload to the surface of Mars per cargo ship, half solar and half propellant production, whose dry mass will be 100 tonnes. That means I get 5MW of solar per trip. With a 20% capacity factor, that's about 1MW on average.

To send 100 tonnes dry mass back costs 70 tonnes of methane. With 100MJ/kg to make methane and 1MW, that means I can produce enough propellant to send that ship back in just 81 days out of the 26 months it takes to do a synod.

Mars has no reason to be energy-starved.

If you want the ship back in one synod, you don't have 26 months, you only have about 3 months to do all that.

And suppose you did.  What did you save?  Even if you could use each ship 10 times, you save less than half the cost, and you need to ship forward additional payload comparable to those ships you sent back.

It makes absolutely no sense to send them back.

Reusability is great and a key to a lot of things, but in this narrow case it is simply counter-productive.
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Offline Robotbeat

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Re: Will Mars-bound Starships actually be reused?
« Reply #83 on: 08/01/2023 08:32 am »
Oh, you missed the point entirely. It has nothing to do with trying to get the ship back in time just with the loaded payload. It's just an exercise in seeing how fast the mass of solar panels and ISRU equipment can "pay" for itself by sending the ship back. It doesn't have to be the same ship.

A starship is worth at least $100 for every kg of its dry mass. If you can get it back to Earth for less than that, it's worth doing. Sure, maybe a lot of the early Starships will be more valuable converted on Mars for other purposes, but that's like trying to reuse external tanks for a space station. You can just get purpose-built stuff for the same cost. Also, it's the same problem as ACES: you'll have way more one-way ships than you'll have uses for.
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Offline Robotbeat

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Re: Will Mars-bound Starships actually be reused?
« Reply #84 on: 08/01/2023 08:37 am »
... Even if you could use each ship 10 times, you save less than half the cost,...
Nah, I don't think that's true. The ships, if one-way, will end up being most of the cost, just like I think the upper stage for Falcon 9 (which is very simple by comparison...) is most of the marginal cost of a F9 mission at this point.

Especially for crewed Starships, those things will not be extremely cheap. They'll probably not be any cheaper per unit dry mass than an airliner and probably more in the early days. They'll probably be most of the marginal cost of a ticket. So getting it back 7-10 times could more than halve the marginal cost of a ticket.

*Plus* you'll need to get a lot of people back anyway.
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Offline Robotbeat

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Re: Will Mars-bound Starships actually be reused?
« Reply #85 on: 08/01/2023 08:39 am »
Sometimes I think some of you are insistent in keeping the costs at more than $1 million per ticket. ;)
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Offline waveney

Re: Will Mars-bound Starships actually be reused?
« Reply #86 on: 08/01/2023 09:25 am »
... Even if you could use each ship 10 times, you save less than half the cost,...
Nah, I don't think that's true. The ships, if one-way, will end up being most of the cost, just like I think the upper stage for Falcon 9 (which is very simple by comparison...) is most of the marginal cost of a F9 mission at this point.

Especially for crewed Starships, those things will not be extremely cheap. They'll probably not be any cheaper per unit dry mass than an airliner and probably more in the early days. They'll probably be most of the marginal cost of a ticket. So getting it back 7-10 times could more than halve the marginal cost of a ticket.

*Plus* you'll need to get a lot of people back anyway.

Largely agree (apart from getting a lot of people back - I think the large majority will stay - how many people who emigrated from Europe to the US returned?).

Crewed starships will be the most valuable of all on Mars.  They have life support.  Which will be very valuable, Mars will need lots of life support.   It maybe that many crewed starships get stripped of useful stuff before they get sent back to be refitted (with newer life support) for the next trip.

Online steveleach

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Re: Will Mars-bound Starships actually be reused?
« Reply #87 on: 08/01/2023 11:29 am »
This talk of hundreds of Starships per synod makes me cringe 😖.

The infrastructure required to handle that amount of traffic on Mars would dwarf LAX.  C’mon guys.  It ain’t going to happen.  Starship will morph into something bigger, faster and more versatile long before we’d see 100 ships travelling together.
A quick check on Wikipedia tells me LAX handles about 1500 flights per day (Atlanta is almost 2000), averaging 116 passengers per flight. And those Starships would arrive over a period of a few weeks.

So maybe 50 to 100 landings per day, which is probably about the level of a small provincial airport.

I agree that we'll probably see bigger vessels before we see fleets that large though.

Offline waveney

Re: Will Mars-bound Starships actually be reused?
« Reply #88 on: 08/01/2023 11:41 am »
By the time Mars needs 100 flights a day, there will be many cities (destinations) on Mars.

Online steveleach

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Re: Will Mars-bound Starships actually be reused?
« Reply #89 on: 08/01/2023 12:26 pm »
Let's take a simple example. Let's say I have 50W_Mars/kg solar panels and 50W/kg of electrolysis and sabatier equipment. And let's say I have 200 tonnes of payload to the surface of Mars per cargo ship, half solar and half propellant production, whose dry mass will be 100 tonnes. That means I get 5MW of solar per trip. With a 20% capacity factor, that's about 1MW on average.

To send 100 tonnes dry mass back costs 70 tonnes of methane. With 100MJ/kg to make methane and 1MW, that means I can produce enough propellant to send that ship back in just 81 days out of the 26 months it takes to do a synod.

Mars has no reason to be energy-starved.
If I'm following you correctly, one ship can deliver the equipment to produce propellant to return about 9 ships per synod? And it will keep on working (with some maintenance and parts replacement) for multiple synods.

So, ball-parking, a single ship should be able to deliver the equipment to return something like 50?

Offline spacenut

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Re: Will Mars-bound Starships actually be reused?
« Reply #90 on: 08/01/2023 01:04 pm »
On Mars they may have to keep several Starships for fuel production for redundancy, as well as fuel storage for refueling Starship.  Other cargo Starships might return.  I would think cargo Starships might have a small crew area on the first Starships for crews.  Early crews might be needed to set up solar panels, hoses/pipelines between Starships for fuel storage and to pump into returning Starships.  They will also need tankage for water storage, not only for making fuel from water, but for making potable water for the early outpost as well as later colony. 

Offline meekGee

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Re: Will Mars-bound Starships actually be reused?
« Reply #91 on: 08/01/2023 01:29 pm »
... Even if you could use each ship 10 times, you save less than half the cost,...
Nah, I don't think that's true. The ships, if one-way, will end up being most of the cost, just like I think the upper stage for Falcon 9 (which is very simple by comparison...) is most of the marginal cost of a F9 mission at this point.

Especially for crewed Starships, those things will not be extremely cheap. They'll probably not be any cheaper per unit dry mass than an airliner and probably more in the early days. They'll probably be most of the marginal cost of a ticket. So getting it back 7-10 times could more than halve the marginal cost of a ticket.

*Plus* you'll need to get a lot of people back anyway.
They may be most of the cost, but reusing them won't reduce the cost by much even under the most optimistic assumptions.
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Offline Coastal Ron

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Re: Will Mars-bound Starships actually be reused?
« Reply #92 on: 08/01/2023 03:03 pm »
Let's take a simple example. Let's say I have 50W_Mars/kg solar panels and 50W/kg of electrolysis and sabatier equipment. And let's say I have 200 tonnes of payload to the surface of Mars per cargo ship, half solar and half propellant production, whose dry mass will be 100 tonnes. That means I get 5MW of solar per trip. With a 20% capacity factor, that's about 1MW on average.

To send 100 tonnes dry mass back costs 70 tonnes of methane. With 100MJ/kg to make methane and 1MW, that means I can produce enough propellant to send that ship back in just 81 days out of the 26 months it takes to do a synod.

Mars has no reason to be energy-starved.

If you want the ship back in one synod, you don't have 26 months, you only have about 3 months to do all that.

And suppose you did.  What did you save?  Even if you could use each ship 10 times, you save less than half the cost, and you need to ship forward additional payload comparable to those ships you sent back.

It makes absolutely no sense to send them back.

Reusability is great and a key to a lot of things, but in this narrow case it is simply counter-productive.

One factor that we need to remember is that who is paying for the Starships? They aren't free, and Elon Musk may not have the financial resources to pay for an infinite number of Starships.

Paying customers going to Mars likely won't start until there is some form of civilization established there, so there will be a period of time where reusing Starships makes financial sense in order to speed up the point where paying customers can pay for a single use Starship trip.
If we don't continuously lower the cost to access space, how are we ever going to afford to expand humanity out into space?

Offline meekGee

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Re: Will Mars-bound Starships actually be reused?
« Reply #93 on: 08/01/2023 06:20 pm »
Sometimes I think some of you are insistent in keeping the costs at more than $1 million per ticket. ;)
Now this cuts deep. Take it back!  :)

We share the goal, you're just wrong in your math.

I'll explain in more detail.

Imagine there were two Mars colonization architects.

One designed a ship that's reusable, can fly 10 times, and can do it so fast it's available for reuse on the next synod.  Let's call him Reusable Robert.

The other designed a ship that flies once, and once landed it becomes storage tanks, batteries, pumps, etc. Lets call her Non-reusable Nelly.

Both Robert and Nelly want to launch double as many ships each synod, starting with 1 ship at synod 0, until they reach 1024 ships.

So: 1,2,4....512, 1024  for a total of 2047 outbound trips.

Nelly has to build 2047 ships.

Robert thought he can save 10x, but even though he always has every ship ever launched available for reuse on each synod, his progression looks like:
1,1,2,4...512 for a total of 1024 ships.
He didn't save 90%..  he saved only 50%!!!

But wait. Common practice is that when you make twice as many ships, your cost per ship drops by 20%.

The cheaper ships lie towards the end, so when you average it out, the savings are not 50% but only 37% (says excel)

But wait - Nelly has a lot of assets on the surface - thousands of tanks for all the ISRU fluids for 100,000 people, batteries, pumps, etc.

Robert meanwhile had to build a much more capable spaceport - he has to turn around hundreds of ships per synod, not just let them land.  That's a tough task even on Earth, not to mention on a colony that's still growing.

On the flip side, Robert has a fleet remaining at the end, but after 20 years - is it really relevant?  Because the ships of the first decade are not the ships of the second decade, or the third..

So in fact Nelly might hit a lower cost to Mars than Robert.



   
« Last Edit: 08/01/2023 09:50 pm by meekGee »
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Offline Robotbeat

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Re: Will Mars-bound Starships actually be reused?
« Reply #94 on: 08/01/2023 08:12 pm »
It doesn’t cost nothing to double how many ships you send every year. By reusing ships, you halve the factory size necessary at each step even if you DO double every synod, so there’s a pretty good case to be made for doing it.
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Offline TheRadicalModerate

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Re: Will Mars-bound Starships actually be reused?
« Reply #95 on: 08/01/2023 08:23 pm »
Does anybody have a good feel for the cost of Starship avionics?  Does anybody have a good feel for how to convert inside-the-magnetosphere MTBF for digital electronics to outside-the-magnetosphere MTBF in the face of solar proton flux and GCR?

I'm guessing that wiring is relatively immune to radiation, but all the actuators, sensors, ethernet hubs, and of course the main computers will soak up roughly the same net energy in one Mars round-trip as an inside-the-magnetosphere Starship will soak up in 50-100 missions.

That would imply a full replacement of all the digital stuff with each Mars mission.  If that's 5% of the total manufacturing and labor cost, it's not a big deal.  If it's 20% of the total cost, that's another story.

Let's take a simple example. Let's say I have 50W_Mars/kg solar panels and 50W/kg of electrolysis and sabatier equipment. And let's say I have 200 tonnes of payload to the surface of Mars per cargo ship, half solar and half propellant production, whose dry mass will be 100 tonnes. That means I get 5MW of solar per trip. With a 20% capacity factor, that's about 1MW on average.

To send 100 tonnes dry mass back costs 70 tonnes of methane. With 100MJ/kg to make methane and 1MW, that means I can produce enough propellant to send that ship back in just 81 days out of the 26 months it takes to do a synod.

Mars has no reason to be energy-starved.

First, is there a particular reason why you're not factoring the cost of LOX?  Raptors run pretty lean, so you have extra electrolysis or MOXIE costs, or you have to recycle H2 via RWGS.  Which one is cheaper, I have no clue.  And of course you have liquefaction and refrigeration costs.¹

But I think you were missing my point.  Power that you dedicate to producing prop for deadhead Starships is power that you don't have to build out your base facilities and spin up all the crucial ISRU industries that we hardly ever talk about:  metallurgy, petrochemicals, lighting/heating/water for agriculture, and of course the creature comforts that convert a base suitable only for the hardest of hard-core settlers into a place that could attract colonists that were <1σ crazy, instead 3-4σ.

SpaceX is going to make money transporting stuff, not operating a colony.  But that biz model means that subsidizing explosive growth of the colony is likely a better deal for their long-term IRR than skimping on the early, low-volume transport.

Again, when you have colonies of millions of people and mature martian industries, you have a lot fewer deadhead runs, and reuse of similarly mature Starships becomes a no-brainer.  But if there are early trades to be made between returning Starships and over-building base/colony facilities, I'm pretty sure that the latter will win handily.  Timing is everything.

___________
¹Update:  I messed this up.  Raptors run a bit rich, actually.  I've been playing with early systems where you might have to use LH2 feedstock before water is in place, and Sabatier under-produces water that's needed for the proper amount of LOX.  You can fix that by taking what water is produced and recycling it via RWGS until you've catalyzed enough extra LOX, but that's a heavier electrolysis load.

If you have water mining up and running, that's not an issue.  However, you still have to re-electrolyze the water produced via Sabatier.  I don't think that chews up more electricity than it would if you just vented the Sabatier water to the atmosphere, though.
« Last Edit: 08/01/2023 08:34 pm by TheRadicalModerate »

Offline Twark_Main

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Re: Will Mars-bound Starships actually be reused?
« Reply #96 on: 08/01/2023 08:56 pm »
Does anybody have a good feel for the cost of Starship avionics?

Starship's avionics are undoubtedly based on F9 heritage, and the F9 avionics package costs about $10,000.

From Elon Musk: Tesla, SpaceX, and the Quest for a Fantastic Future by Ashlee Vance:

Quote
Musk wanted the bulk of a rocket’s computing systems to cost no more than $10,000. It was an insane figure by aerospace industry standards, where the avionics systems for a rocket typically cost well over $10 million. “In traditional aerospace, it would cost you more than ten thousand dollars just for the food at a meeting to discuss the cost of the avionics,” Watson said. During the job interview, Watson promised Musk that he could do the improbable and deliver the $10,000 avionics system.

...Watson and other engineers built out the complete computing systems for Dragon and then adapted the technology for Falcon 9. The result was a fully redundant avionics platform that used a mix of off-the-shelf computing gear and products built in-house by SpaceX. It cost a bit more than $10,000 but came close to meeting Musk’s goal.

One of the advantages of large rockets is that your avionics don't really get any heavier/costlier, so you achieve better amortization.
« Last Edit: 08/01/2023 08:57 pm by Twark_Main »

Offline TheRadicalModerate

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Re: Will Mars-bound Starships actually be reused?
« Reply #97 on: 08/01/2023 09:07 pm »
One of the advantages of large rockets is that your avionics don't really get any heavier/costlier, so you achieve better amortization.

There are a lot more controllers involved, both for sensors and actuators.  Those hook up to more engines, more valves for more COPVs, weird aerosurfaces, copious temperature and pressure sensors, etc.

It's pretty easy to throw shielding at the main computers, but the stuff on the other end is just as important and harder to service.  And shielding it in a tight mass budget is impractical.

Offline meekGee

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Re: Will Mars-bound Starships actually be reused?
« Reply #98 on: 08/01/2023 10:04 pm »
Sometimes I think some of you are insistent in keeping the costs at more than $1 million per ticket. ;)
Now this cuts deep. Take it back!  :)

We share the goal, you're just wrong in your math.

I'll explain in more detail.

Imagine there were two Mars colonization architects.

One designed a ship that's reusable, can fly 10 times, and can do it so fast it's available for reuse on the next synod.  Let's call him Reusable Robert.

The other designed a ship that flies once, and once landed it becomes storage tanks, batteries, pumps, etc. Lets call her Non-reusable Nelly.

Both Robert and Nelly want to launch double as many ships each synod, starting with 1 ship at synod 0, until they reach 1024 ships.

So: 1,2,4....512, 1024  for a total of 2047 outbound trips.

Nelly has to build 2047 ships.

Robert thought he can save 10x, but even though he always has every ship ever launched available for reuse on each synod, his progression looks like:
1,1,2,4...512 for a total of 1024 ships.
He didn't save 90%..  he saved only 50%!!!

But wait. Common practice is that when you make twice as many ships, your cost per ship drops by 20%.

The cheaper ships lie towards the end, so when you average it out, the savings are not 50% but only 37% (says excel)

But wait - Nelly has a lot of assets on the surface - thousands of tanks for all the ISRU fluids for 100,000 people, batteries, pumps, etc.

Robert meanwhile had to build a much more capable spaceport - he has to turn around hundreds of ships per synod, not just let them land.  That's a tough task even on Earth, not to mention on a colony that's still growing.

On the flip side, Robert has a fleet remaining at the end, but after 20 years - is it really relevant?  Because the ships of the first decade are not the ships of the second decade, or the third..

So in fact Nelly might hit a lower cost to Mars than Robert.
   
It doesn’t cost nothing to double how many ships you send every year. By reusing ships, you halve the factory size necessary at each step even if you DO double every synod, so there’s a pretty good case to be made for doing it.

So Nelly has a factory on Earth that's twice as large, but Robert has to build a refueling and relaunch operation that has to match the incoming traffic, pretty much in real time.  That's 100x as large and complicated as Nelly's requirements!

Building large and complex infrastructure on Earth is hard enough.  But building it on Mars, practically in vacuum, and with very limited resources, is not only infinitely more difficult, but comes at the expense of other colony efforts.

A colony needs to build Power, ISRU, habitation and basically an entire industry - and now you're adding a launch operation that has no purpose other than to reduce construction requirements on Earth.

Nelly needs only to build enough launch capacity to enable some partial crew fly backs, a small fraction of the total volume of incoming traffic.

I don't think you're reducing the cost per colonist here.
« Last Edit: 08/01/2023 10:24 pm by meekGee »
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Offline Robotbeat

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Re: Will Mars-bound Starships actually be reused?
« Reply #99 on: 08/01/2023 10:04 pm »
I think it’s fair to say the avionics don’t scale much with size, only with vehicle complexity.
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Tags: SpaceX Starship Mars reuse 
 

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