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On any given day, SpaceX is probably launching a Falcon 9 rocket, rolling one out to the launch pad or bringing one back into port. With three active Falcon 9 launch pads and an increasing cadence at the Starbase facility in Texas, SpaceX's teams are often doing all three.
The company achieved another milestone Friday with the 25th successful launch and landing of a single Falcon 9 booster. This rocket, designated B1067, launched a batch of 21 Starlink Internet satellites from Cape Canaveral Space Force Station, Florida. //
But SpaceX's accomplishment of 25 flights offers an opportunity to step back and take in some context. The newest and final iteration of the Falcon 9 design, known as Block 5, debuted in 2018. At the time, SpaceX officials said they planned to fly each booster 10 times before standing down for more thorough refurbishment.
SpaceX now plans to launch each Falcon 9 booster up to 40 times. Engineers temporarily removed two Falcon 9 boosters from SpaceX's launch rotation in 2023 for in-depth inspections after their 15th flight. That allowed SpaceX to extend each booster's certification to 20 flights, and last year, officials announced they were going for 40. //
SpaceX is also recovering and reusing payload fairings, the shell that encloses satellite payloads during their initial climb through the atmosphere. Last month, the company confirmed it flew a fairing shell for the 22nd time, another new record. SpaceX's factory in Hawthorne, California, must also churn out new upper stages for each Falcon 9 and Falcon Heavy flight. That's 135 of these multimillion-dollar stages for each Falcon mission in the last 365 days, or one flight (and one new upper stage) every 2.7 days. //
Imagine, for a moment, the sprawling footprint and bloated headcount of SpaceX's factory if it had to manufacture a new Falcon 9 booster, nine engines, and a payload fairing set every 2.7 days. How cost-effective could that be? Would it even be possible? It's mind-boggling enough to visualize the blistering production pace for Falcon 9's upper stages in Hawthorne or SpaceX's Starlink satellites in Redmond, Washington. //
Elon Musk, SpaceX's founder and CEO, has suggested that his company must produce 100 or more Starships per year to fulfill his Mars settlement ambitions, even with full reusability. //
While SpaceX's competency with reusing Falcon 9 boosters gets a lot of attention—landing a rocket is still incredible, even after seeing it nearly 400 times—its manufacturing prowess with Falcon 9 upper stages suggests that building 100 Starships each year just might be doable someday.