SpaceX reusable launch system development program: Difference between revisions

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{{Private spaceflight}}
 
[[SpaceX]] has [[private spaceflight|privately funded]] the development of [[Orbital spaceflight|orbital]] [[spacecraft|launch system]]s that can be [[reusable launch vehicle|reused]] many times, similar to the reusability of [[aircraft]]. SpaceX has developed technologies oversince the last decade2010s to facilitate full and rapid reuse of space [[launch vehicle]]s. The project's long-term objectives include returning a launch vehicle [[multistage rocket|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 entry|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.<ref name="pm20120207">{{cite news |url=http://www.popularmechanics.com/science/space/rockets/elon-musk-on-spacexs-reusable-rocket-plans-6653023 |title=Elon Musk on SpaceX's Reusable Rocket Plans |work=Popular Mechanics |last=Simberg |first=Rand |date=February 8, 2012 |access-date=February 7, 2012 |archive-date=October 6, 2014 |archive-url=https://web.archive.org/web/20141006092432/http://www.popularmechanics.com/science/space/rockets/elon-musk-on-spacexs-reusable-rocket-plans-6653023 |url-status=live }}</ref> Development of reusable second stages for Falcon 9 was later abandoned in favor of developing [[SpaceX Starship|Starship]].<ref name="nosecondstagereuse" /> However, SpaceX still developed reusable payload fairings for the Falcon 9.<ref name="sn20170330" />
 
The program was announced in 2011. SpaceX first achieved a [[Falcon 9 Flight 20|successful landing and recovery of a first stage]] in December 2015. The [[SES-10|first re-flight of a landed first stage]] occurred in March 2017<ref name=sn20170330/> with the second occurring in June 2017, that one only five months after the maiden flight of the booster.<ref name=sir-20170626 /> The third attempt occurred in October 2017 with the [[SES-11]]/[[EchoStar-105]] mission. Reflights of refurbished first stages then became routine. In May 2021, B1051 became the first booster to launch ten missions.<ref>{{Cite web|last1=Sesnic|first1=Trevor|last2=Fletcher|first2=Colin|last3=Kanayama|first3=Lee|date=2021-05-08|title=SpaceX flies historic 10th mission of a Falcon 9 as Starlink constellation expands|url=https://www.nasaspaceflight.com/2021/05/historic-10th-falcon9-reflight/|access-date=2021-05-19|website=NASASpaceFlight.com|language=en-US|archive-date=May 16, 2021|archive-url=https://web.archive.org/web/20210516121203/https://www.nasaspaceflight.com/2021/05/historic-10th-falcon9-reflight/|url-status=live}}</ref>
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== History ==
[[File:SpaceX rockets.svg|thumb|upright=2|right|From left to right, [[Falcon 1]], [[Falcon 9 v1.0]], three versions of [[Falcon 9 v1.1]], three versions of [[Falcon 9 Full Thrust|Falcon 9 v1.2 (Full Thrust)]], three versions of [[Falcon 9 Block 5]], [[Falcon Heavy]], three versions of [[Falcon Heavy Block 5]] and [[SpaceX Starship|Starship]] Block 1. The SpaceX reusable rocket technology is being developed for Falcon 9 v1.2, Falcon Heavy and Starship.]]
 
SpaceX attempted to land the first stage of the [[Falcon 1#Reusability|Falcon 1 by parachute]], but the stage did not survive atmosphere re-entry. They continued to experiment unsuccessfully with parachutes on the earliest [[Falcon 9]] flights after 2010. SpaceX subsequently switched to developing a [[Retropropulsion|powered descent]] [[VTVL|landing]] system.<ref name=nsf20170330>{{cite news |last=Graham |first=William |url=https://www.nasaspaceflight.com/2017/03/spacex-historic-falcon-9-re-flight-ses-10/ |title=SpaceX conducts historic Falcon 9 re-flight with SES-10 – Lands booster again |work=[[NASASpaceFlight.com]] |date=2017-03-30 |access-date=2017-05-27 |quote='The earliest Falcon 9 launches carried parachutes which were to have been used to recover the first stage. However, this was abandoned due to the stage disintegrating during reentry, before the parachutes could be deployed. Instead, SpaceX began to investigate using the stage’s engines to make a powered descent and landing. Alongside this, an improved Falcon 9 vehicle, the Falcon 9 v1.1, was developed.' |archive-date=May 17, 2017 |archive-url=https://web.archive.org/web/20170517125334/https://www.nasaspaceflight.com/2017/03/spacex-historic-falcon-9-re-flight-ses-10/ |url-status=live }}</ref>
 
A description of the reusable launch system was outlined in September 2011. SpaceX said it would attempt to develop powered descent and recovery of both Falcon 9 stages{{mdash}}a fully vertical takeoff, vertical landing ([[VTVL]]) rocket. The company produced an animated video of the first stage returning tail-first for a powered descent and the second stage with a heat shield, reentering head first before rotating for a powered descent.<ref name="wp20110929">{{cite video |url=https://www.youtube.com/watch?v=RkvLQdzZRFo |title=SpaceX Chief Details Reusable Rocket |date=September 29, 2011 |language=en-us |access-date=April 9, 2016 |via=Associated Press |work=Washington Post}}</ref><ref name="sdc20110930">{{cite news |url=http://www.space.com/13140-spacex-private-reusable-rocket-elon-musk.html |title=SpaceX Unveils Plan for World's First Fully Reusable Rocket |newspaper=Space.com |last=Wall |first=Mike |date=September 30, 2011 |access-date=October 11, 2011 |archive-date=October 10, 2011 |archive-url=https://web.archive.org/web/20111010191516/http://www.space.com/13140-spacex-private-reusable-rocket-elon-musk.html |url-status=live }}</ref><ref name="SpaceX Video from SpaceX. com">{{cite web |url=http://www.spacex.com/assets/video/spacex-rtls-green.mp4 |title=Falcon 9 Return to Launch Site |format=video |work=SpaceX.com |archive-url=https://web.archive.org/web/20111011221641/http://www.spacex.com/assets/video/spacex-rtls-green.mp4 |archive-date=October 11, 2011}}</ref><ref name="npc20110929">{{cite AV media |url=https://www.youtube.com/watch?v=xrVD3tcVWTY |title=National Press Club: The Future of Human Spaceflight |medium=video |work=NPC video repository |date=September 29, 2011 |people=Mark Hamrick, Elon Musk |publisher=National Press Club |quote=@18:15 "It is a very tough engineering problem—and it wasn't something that I thought, wasn't sure it could be solved for a while. But then, just relatively recently, in the last 12 months or so, I've come to the conclusion that it can be solved. And SpaceX is going to try to do it. Now, we could fail. I am not saying we are certain of success here, but we are going to try to do it. And we have a design that, on paper, doing the calculations, doing the simulations, it does work. Now we need to make sure that those simulations and reality agree, because generally when they don't, reality wins. So that's to be determined."}}</ref><!-- ←the original source was http://www.c-span.org/Events/National-Press-Club-The-Future-of-Human-Spaceflight/10737424486/ |title=National Press Club: The Future of Human Spaceflight |work=C-SPAN.org |date=September 29, 2011 --- but that link has gone dead. Found another copy on the NPC video repository on YouTube --> In September 2012, SpaceX began flight tests on a prototype reusable first stage with the suborbital [[GrasshopperSpaceX (rocket)Grasshopper|Grasshopper rocket]].<ref name="cl20121224" /> Those tests continued into 2014, including testing of a second and larger prototype vehicle, [[F9R Dev1]].
 
News of the Grasshopper test rocket had become public a few days earlier, when the [[Federal Aviation Administration|US Federal Aviation Administration]] released a [[National Environmental Policy Act|draft Environmental Impact Assessment]] for the SpaceX Test Site in Texas, and the space media had reported it.<ref name="faa20110922">{{cite web |url=http://www.faa.gov/about/office_org/headquarters_offices/ast/media/20110922%20spacex%20grasshopper%20draft%20ea.final.pdf |title=Draft Environmental Assessment for Issuing an Experimental Permit to SpaceX for Operation of the Grasshopper Vehicle at the McGregor Test Site, Texas |publisher=Federal Aviation Administration |date=September 22, 2011 |access-date=November 21, 2013 |archive-date=January 12, 2013 |archive-url=https://web.archive.org/web/20130112212209/http://www.faa.gov/about/office_org/headquarters_offices/ast/media/20110922%20spacex%20grasshopper%20draft%20ea.final.pdf |url-status=live }}</ref><ref name="satspot20110926" /> In May 2012, SpaceX obtained a set of atmospheric test data for the recovery of the Falcon 9 first stage based on 176 test runs in the [[NASA]] [[Marshall Space Flight Center]] [[wind tunnel]] test facility. The work was contracted out by SpaceX under a reimbursable [[Space Act Agreement]] with NASA.<ref name="sn20120528">{{cite news |url=http://www.spacenews.com/article/nasa-finishes-wind-tunnel-testing-falcon-9-1st-stage |title=NASA Finishes Wind-tunnel Testing of Falcon 9 1st Stage |work=Space News |date=May 28, 2012 |access-date=June 26, 2012 }}</ref>
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In November 2012, CEO [[Elon Musk]] announced plans to build a second, much larger, [[SpaceX super-heavy lift launch vehicle|reusable rocket system]] powered by [[LOX]]/[[liquid methane|methane]] rather than LOX/[[RP-1]] used on Falcon 9 and Falcon Heavy. The new system was to be "an evolution of SpaceX's Falcon 9 booster", and SpaceX reiterated their commitment to develop a breakthrough in vertical landing technology.<ref name="sdc20121123">{{cite news |url=http://www.space.com/18596-mars-colony-spacex-elon-musk.html |title=Huge Mars Colony Eyed by SpaceX Founder Elon Musk |work=Space.com |last=Coppinger |first=Rod |date=November 23, 2012 |access-date=November 25, 2012 |quote=much bigger [than Falcon 9], but I don’t think we’re quite ready to state the payload. We’ll speak about that next year. |archive-date=June 28, 2013 |archive-url=https://web.archive.org/web/20130628154029/http://www.space.com/18596-mars-colony-spacex-elon-musk.html |url-status=live }}</ref> By the end of 2012, the demonstration test vehicle, Grasshopper, had made three VTVL test flights{{mdash}}including a 29-second hover flight to {{convert|40|m|sp=us}} on December 17, 2012.<ref name="cl20121224">{{cite news |url=http://cosmiclog.nbcnews.com/_news/2012/12/23/16114180-spacex-launches-its-grasshopper-rocket-on-12-story-high-hop-in-texas |title=SpaceX launches its Grasshopper rocket on 12-story-high hop in Texas |work=NBC News{{\}}Cosmic Log |last=Boyle |first=Alan |date=December 24, 2012 |access-date=December 25, 2012 |archive-date=March 3, 2016 |archive-url=https://web.archive.org/web/20160303194358/http://cosmiclog.nbcnews.com/_news/2012/12/23/16114180-spacex-launches-its-grasshopper-rocket-on-12-story-high-hop-in-texas |url-status=live }}</ref> In early March 2013, SpaceX successfully tested Grasshopper for a fourth time when it flew to an altitude of over {{convert|80|m|sp=us}}.<ref name=nsj20130309/>
 
In March 2013, SpaceX announced that it would instrument and equip subsequent Falcon 9 first-stages as controlled descent test vehicles, with plans for over-water propulsively decelerated simulated landings beginning in 2013, with the intent to return the vehicle to the launch site for a powered landing{{mdash}}possibly as early as mid-2014.<ref name="pa20130328">{{cite news |url=http://www.parabolicarc.com/2013/03/28/dragon-post-mission-press-conference-notes/ |title=Dragon Post-Mission Press Conference Notes |work=Parabolic Arc |last=Messier |first=Doug |date=March 28, 2013 |access-date=March 30, 2013 |quote=Q. What is strategy on booster recover? Musk: Initial recovery test will be a water landing. First stage continue in ballistic arc and execute a velocity reduction burn before it enters atmosphere to lessen impact. Right before splashdown, will light up the engine again. Emphasizes that we don’t expect success in the first several attempts. Hopefully next year with more experience and data, we should be able to return the first stage to the launch site and do a propulsion landing on land using legs. Q. Is there a flight identified for return to launch site of the booster? Musk: No. Will probably be the middle of next year. |archive-date=May 31, 2013 |archive-url=https://web.archive.org/web/20130531230305/http://www.parabolicarc.com/2013/03/28/dragon-post-mission-press-conference-notes/ |url-status=live }}</ref> The April 2013 draft [[Environmental impact statement|Environmental Impact Statement]] for the proposed [[SpaceX South Texas Launch Site]] includes specific accommodations for return of the Falcon 9 first-stage boosters to the launch site.<ref name="faa201304v1">{{cite report|url=http://1.usa.gov/YtxBzo |title=Draft Environmental Impact Statement: SpaceX Texas Launch Site |publisher=Federal Aviation Administration{{\}}Office of Commercial Space Transportation |last=Nield |first=George C. |volume=1 |date=April 2013 |url-status=dead |archive-url=https://web.archive.org/web/20131207085028/http://www.faa.gov/about/office_org/headquarters_offices/ast/environmental/nepa_docs/review/documents_progress/spacex_texas_launch_site_environmental_impact_statement/media/SpaceX_Texas_Launch_Site_Draft_EIS_V1.pdf |archive-date=December 7, 2013 }}</ref> Elon Musk first publicly referred to the reusable Falcon 9 as the [[Falcon 9-R]] in April 2013.<ref name="musk20130428" />
 
In September 2013, SpaceX successfully relit three engines of a spent booster on an orbital launch, and the booster re-entered the atmosphere at hypersonic speed without burning up.<ref name=fp20131209/> With the data collected from the first flight test of a booster-controlled descent from high altitude, coupled with the technological advancements made on the Grasshopper low-altitude landing demonstrator, SpaceX announced it believed it was ready to test a full land-recovery of a booster stage.<ref name=pm20130930/> Based on the positive results from the first high-altitude flight test, SpaceX advanced the expected date of a test from mid-2014 to early 2015{{clarify|date=September 2016}}, with the intention of doing so on the [[SpaceX CRS-3|next Space Station cargo resupply flight]] pending regulatory approvals.<ref name="bbc20130930" /><ref name="pa20130930" /> That flight took place on April 18, 2014.<ref name=aw20140428a>{{cite news |last=Norris |first=Guy |title=SpaceX Plans For Multiple Reusable Booster Tests |url=http://aviationweek.com/space/spacex-plans-multiple-reusable-booster-tests |access-date=May 17, 2014 |newspaper=Aviation Week |date=April 28, 2014 |quote=The April 17 F9R Dev 1 flight, which lasted under 1 min., was the first vertical landing test of a production-representative recoverable Falcon 9 v1.1 first stage, while the April 18 cargo flight to the ISS was the first opportunity for SpaceX to evaluate the design of foldable landing legs and upgraded thrusters that control the stage during its initial descent. |archive-date=April 26, 2014 |archive-url=https://web.archive.org/web/20140426201818/http://aviationweek.com/space/spacex-plans-multiple-reusable-booster-tests |url-status=live }}</ref><ref name="ut20140419">{{cite news |url=http://www.universetoday.com/111377/spacex-makes-strides-towards-1st-stage-falcon-rocket-recovery-during-space-station-launch/ |title=SpaceX Makes Strides Towards 1st Stage Falcon Rocket Recovery during Space Station Launch |work=Universe Today |last=Kremer |first=Ken |date=April 19, 2014 |access-date=April 19, 2014 |archive-date=April 19, 2014 |archive-url=https://web.archive.org/web/20140419222428/http://www.universetoday.com/111377/spacex-makes-strides-towards-1st-stage-falcon-rocket-recovery-during-space-station-launch/ |url-status=live }}</ref>
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* New [[Spacecraft attitude control|attitude control]] technology for the booster to bring the descending [[rocket body]] through the atmosphere in a manner conducive both to non-destructive return and [[Aerodynamic control surfaces|sufficient aerodynamic control]] such that the terminal phase of the [[VTVL|landing]] is possible.<ref name="pa20140114vid">
{{cite video |url=https://www.youtube.com/watch?v=XtNgWK4mm0M |title=Singapore Satellite Industry Forum 2013 – Opening Keynote |date=June 17, 2013 |language=en |access-date=April 9, 2016 |people=Gwynne Shotwell}}</ref> This includes sufficient roll [[Control system|control authority]] to keep the rocket from spinning excessively as occurred on the [[Falcon 9 Flight 6#Post-mission launch vehicle testing|first high-altitude flight test]] in September 2013, where the roll rate exceeded the capabilities of the booster [[attitude control system]] (ACS) and the fuel in the tanks "centrifuged" to the side of the tank shutting down the single engine involved in the low-altitude deceleration maneuver.<ref name="pa20130930" /><ref name="tss20140321b">{{cite AV media |url=http://archived.thespaceshow.com/shows/2212-BWB-2014-03-21.mp3 |title=Broadcast 2212: Special Edition, interview with Gwynne Shotwell |date=March 21, 2014 |medium=audio file |language=en |publisher=The Space Show |time=51;50–52;55 |access-date=March 22, 2014 |archive-url=https://web.archive.org/web/20140322013556/http://archived.thespaceshow.com/shows/2212-BWB-2014-03-21.mp3 |archive-date=March 22, 2014 |url-status=dead |format=mp3 |id=2212 |people=Gwynne Shotwell}}</ref> The technology needs to handle the transition from the vacuum of space at [[hypersonic]] conditions, decelerating to [[supersonic]] velocities and passing through [[Transonic buffet|transonic]] [[Buffet (turbulence)|buffet]], before relighting one of the main-stage engines at [[terminal velocity]].<ref name=pm20130930/>
* Hypersonic [[grid fin]]s were added to the booster test vehicle design beginning on the [[Falcon 9 Flight 14|fifth ocean controlled-descent test flight]] in 2014 in order to enable precision landing. Arranged in an "X" configuration, the grid fins control the descending rocket's [[lift vector]] once the vehicle has returned to the atmosphere to enable a much more precise [[Landing ellipse|landing ___location]].<ref name=sx20141216>{{cite webnews |title=X MARKS THE SPOT: FALCON 9 ATTEMPTS OCEAN PLATFORM LANDING |url=http://www.spacex.com/news/2014/12/16/x-marks-spot-falcon-9-attempts-ocean-platform-landing |publishernewspaper=SpaceX |access-date=December 17, 2014 |date=December 16, 2014 |quote=A key upgrade to enable precision targeting of the Falcon 9 all the way to touchdown is the addition of four hypersonic grid fins placed in an X-wing configuration around the vehicle, stowed on ascent and deployed on reentry to control the stage’s lift vector. Each fin moves independently for roll, pitch and yaw, and combined with the engine gimbaling, will allow for precision landing – first on the autonomous spaceport drone ship, and eventually on land. |archive-date=December 17, 2014 |archive-url=https://web.archive.org/web/20141217062424/http://www.spacex.com/news/2014/12/16/x-marks-spot-falcon-9-attempts-ocean-platform-landing |url-status=live |last1=Post |first1=Hannah }}<!-- quotation added as SpaceX often removes these sorts of news source pages after some months --></ref><ref name=blackmore2016/> Iteration on the design continued into 2017. Larger and more robust grid fins, made from forged [[titanium]] and left unpainted, were first tested in June 2017, and have been used on all reusable Block 5 Falcon 9 first stages since May 2018.<ref>{{cite web|url=https://www.nasaspaceflight.com/2017/06/spacex-falcon-9-iridium-next-2-launch/|title=SpaceX Doubleheader Part 2 – Falcon 9 conducts Iridium NEXT-2 launch – NASASpaceFlight.com|website=www.nasaspaceflight.com|date=June 25, 2017|access-date=July 4, 2017|archive-date=November 11, 2020|archive-url=https://web.archive.org/web/20201111202928/https://www.nasaspaceflight.com/2017/06/spacex-falcon-9-iridium-next-2-launch/|url-status=live}}</ref>
[[File:Falcon 9 with CRS-3 Dragon in SLC-40 hangar (16855338881).jpg|thumb|left|Falcon 9 v1.1 with landing legs attached, in stowed position as the rocket is prepared for launch in its hangar]]
* The [[Rocket engine throttling|rocket engine needs to be throttleable]] to achieve zero velocity at the same time the rocket reaches the ground. Even the lowest possible thrust of a single [[Merlin 1D]] engine exceeds the weight of the nearly empty Falcon 9 booster core, therefore the rocket cannot hover.<ref name=fg20130321>{{cite news |last=Rosenberg |first=Zach |title=SpaceX Merlin 1D qualified for flight |url=http://www.flightglobal.com/news/articles/spacex-merlin-1d-qualified-for-flight-383738/ |access-date=March 18, 2014 |newspaper=Flightglobal |date=March 21, 2013 |archive-date=October 30, 2013 |archive-url=https://web.archive.org/web/20131030135922/http://www.flightglobal.com/news/articles/spacex-merlin-1d-qualified-for-flight-383738/ |url-status=live }}</ref><ref name=slr20140312>{{cite web |title=SpaceX Falcon 9 v1.1 Data Sheet |url=http://www.spacelaunchreport.com/falcon9v1-1.html |publisher=Space Launch Report |access-date=March 18, 2014 |date=March 12, 2014 |archive-date=November 11, 2020 |archive-url=https://web.archive.org/web/20201111220657/https://www.spacelaunchreport.com/falcon9v1-1.html |url-status=live }}</ref><ref name=blackmore2016/>
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* A large [[floating landing platform]] for launches where the first stage does not have sufficient fuel to return to the launch site. As of 2022, SpaceX built three [[autonomous spaceport drone ship]]s, one operating the West coast and two on the East coast of the United States.
* A [[thermal protection system]] to avoid damage to the first stage when re-entering the atmosphere.<ref>{{cite news|url=https://spaceflightnow.com/2018/05/11/spacex-debuts-an-improved-human-rated-model-of-the-falcon-9-rocket/|title=SpaceX debuts new model of the Falcon 9 rocket designed for astronauts|date=11 May 2018|access-date=August 23, 2019|archive-date=April 1, 2021|archive-url=https://web.archive.org/web/20210401055341/https://spaceflightnow.com/2018/05/11/spacex-debuts-an-improved-human-rated-model-of-the-falcon-9-rocket/|url-status=live}}</ref>
* Lightweight, deployable [[Launch vehicle landing gear|landing gear]] for the booster stage.<ref name="satspot20110926" /><ref name=blackmore2016>{{cite journal |title=Autonomous Precision Landing of Space Rockets |journal=The Bridge, National Academy of Engineering |date=Winter 2016 |last=Blackmore |first=Lars |volume=46 |issue=4 |pages=15–20 |issn=0737-6278 |url=http://web.mit.edu/larsb/www/nae_bridge_2016.pdf |access-date=January 15, 2017 |archive-date=January 10, 2017 |archive-url=https://web.archive.org/web/20170110121559/http://web.mit.edu/larsb/www/nae_bridge_2016.pdf |url-status=live }}</ref> In May 2013, the design was shown to be a nested, telescoping piston on an A-frame. The total span of the four [[carbon fiber]]/[[aluminum]] extensible landing legs<ref name="sxn20130729legs">{{cite webnews |url=http://www.spacex.com/news/2013/03/26/landing-leg |title=Landing Legs |work=SpaceX.com |date=July 29, 2013 |access-date=December 4, 2013 |quote=The Falcon 9 first stage carries landing legs which will deploy after stage separation and allow for the rocket’s soft return to Earth. The four legs are made of state-of-the-art carbon fiber with aluminum honeycomb. Placed symmetrically around the base of the rocket, they stow along the side of the vehicle during liftoff and later extend outward and down for landing. |archive-date=May 20, 2015 |archive-url=https://web.archive.org/web/20150520100337/http://www.spacex.com/news/2013/03/26/landing-leg |url-status=live |last1=Shanklin |first1=Emily }}</ref><ref name="sxn20130802fh_legs">{{cite web |url=http://www.spacex.com/news/2013/04/12/falcon-heavy-landing-legs |title=Falcon Heavy Landing Legs |work=SpaceX.com |date=April 12, 2013 |access-date=December 4, 2013 |quote=The Falcon Heavy first stage center core and boosters each carry landing legs, which will land each core safely on Earth after takeoff. After the side boosters separate, the center engine in each will burn to control the booster’s trajectory safely away from the rocket. The legs will then deploy as the boosters turn back to Earth, landing each softly on the ground. The center core will continue to fire until stage separation, after which its legs will deploy and land it back on Earth as well. The landing legs are made of state-of-the-art carbon fiber with aluminum honeycomb. The four legs stow along the sides of each core during liftoff and later extend outward and down for landing. |archive-date=June 11, 2015 |archive-url=https://web.archive.org/web/20150611163359/http://www.spacex.com/news/2013/04/12/falcon-heavy-landing-legs |url-status=dead }}</ref> is approximately {{convert|60|ft|m|order=flip|sp=us}}, and weigh less than {{convert|2100|kg}}. Deployment system uses high-pressure [[Helium]] as the [[working fluid]].<ref name="musk20130502">{{cite news |url=http://www.newspacewatch.com/articles/spacex-shows-a-leg-for-the-quotf-ninerquot.html |title=SpaceX shows a leg for the "F-niner" |work=NewSpace Watch |last=Lindsey |first=Clark |date=May 2, 2013 |access-date=May 2, 2013 <!--REMOVED https://archive.today/ archive link, as a wikibot reports that is is on some sort of "local blacklist". See page history on 2016-04-05 for more info -->|archive-url=https://archive.today/20130630001715/http://www.newspacewatch.com/articles/spacex-shows-a-leg-for-the-quotf-ninerquot.html |archive-date=June 30, 2013 |url-status=live |quote=F9R (pronounced F-niner) shows a little leg. Design is a nested, telescoping piston w A frame... High pressure helium. Needs to be ultra light. |url-access=subscription}}</ref><ref name=nsf20140228>{{cite news |last=Bergin |first=Chris |title=SpaceX outlines CRS-3 landing legs plan toward first stage recovery ambitions |url=http://www.nasaspaceflight.com/2014/02/spacex-crs-3-landing-legs-plan-first-stage-recovery-ambitions/ |access-date=May 10, 2014 |newspaper=NASAspaceflight.com |date=February 28, 2014 |archive-date=June 1, 2014 |archive-url=https://web.archive.org/web/20140601134441/http://www.nasaspaceflight.com/2014/02/spacex-crs-3-landing-legs-plan-first-stage-recovery-ambitions/ |url-status=live }}</ref> With [[Falcon 9 first-stage landing tests#Flight 25|Flight 25]] it was announced that each landing leg contained a "crush core", to absorb the impact of landing for particularly hard landings.<ref name="space.com">{{cite news |last1=Wall |first1=Mike |title=SpaceX's Leaning Rocket Tower Comes Ashore (Photos) |url=http://www.space.com/33102-spacex-leaning-rocket-comes-ashore-photos.html |access-date=June 7, 2016 |date=June 7, 2016 |archive-date=June 8, 2016 |archive-url=https://web.archive.org/web/20160608132146/http://www.space.com/33102-spacex-leaning-rocket-comes-ashore-photos.html |url-status=live }}</ref><ref>{{Cite web |url=https://twitter.com/elonmusk/status/736328917317910528?lang=en |title=Elon Musk on Twitter |website=Twitter |access-date=June 8, 2016 |quote=The crush core in the Falcon legs is reusable after soft landings, but needs to be replaced after hard. |archive-date=September 3, 2017 |archive-url=https://web.archive.org/web/20170903090316/https://twitter.com/elonmusk/status/736328917317910528?lang=en |url-status=live }}</ref>
 
== Economics of rocket reuse ==
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== Falcon 9 reusability development ==
In 2013 SpaceX was testing reusable technologies both for its [[Booster (rocketry)|first-stage booster]] launch vehicle designs (with three test vehicles: [[GrasshopperSpaceX (rocket)Grasshopper|Grasshopper]], [[F9R Dev1]], and [[F9R Dev2]]) – and for its new reusable [[SpaceX Dragon 2]] [[space capsule]] (with a low-altitude test vehicle called [[DragonFly (rocket)|DragonFly]]).
 
SpaceX has publicly disclosed a multi-element, incremental test program for booster stages that includes four aspects:
* low-altitude (less than {{convert|760|m|ft|-2|disp=x|/|abbr=on}}<ref name="faa20110922" /><ref name=wt20130508>{{cite news |last=Abbott |first=Joseph |title=SpaceX's Grasshopper leaping to NM spaceport |url=http://www.wacotrib.com/news/business/spacex-s-grasshopper-leaping-to-nm-spaceport/article_de2126cd-d6ec-563b-b84b-532641e709e3.html |access-date=October 25, 2013 |newspaper=Waco Tribune |date=May 8, 2013 |archive-date=August 5, 2020 |archive-url=https://web.archive.org/web/20200805174829/https://wacotrib.com/news/business/spacex-s-grasshopper-leaping-to-nm-spaceport/article_de2126cd-d6ec-563b-b84b-532641e709e3.html |url-status=live }}</ref>), low-velocity testing of its single-engine [[GrasshopperSpaceX (rocket)Grasshopper|Grasshopper]] technology-demonstrator at its Texas test site
* low-altitude (less than {{convert|3000|m|ft|-2|disp=x|/|abbr=on}}), low-velocity testing of a much larger, second-generation, three-engine test vehicle called [[F9R Dev1]]. The second generation vehicle includes extensible landing legs and will be tested at the Texas test site<ref name=tsr20140505>{{cite news |last=Foust |first=Jeff |title=Following up: reusability, B612, satellite servicing |url=http://www.thespacereview.com/article/2505/1 |access-date=May 6, 2014 |newspaper=The Space Review |date=May 5, 2014 |archive-date=May 6, 2014 |archive-url=https://web.archive.org/web/20140506133336/http://www.thespacereview.com/article/2505/1 |url-status=live }}</ref>
* high-altitude, mid-velocity testing was planned but cancelled in favor of [[Falcon 9 first-stage landing tests|post-mission re-entry tests of first-stage boosters]]. It would have used F9R Dev2 at a SpaceX leased facility at [[Spaceport America]] in [[New Mexico]].
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==== Grasshopper ====
{{main|SpaceX Grasshopper{{!}}Grasshopper (rocket)}}
 
Grasshopper, the company's first [[VTVL]] test vehicle, consisted of a [[Falcon 9 v1.0]] first-stage tank, a single [[Merlin 1D|Merlin-1D]] engine, and four permanently attached steel landing legs. It stood {{convert|106|ft}} tall.<ref name="satspot20110926">{{cite news |url=http://satellite.tmcnet.com/topics/satellite/articles/222324-spacex-plans-test-reusable-suborbital-vtvl-rocket-texas.htm |title=SpaceX Plans to Test Reusable Suborbital VTVL Rocket in Texas |newspaper=Satellite Spotlight |last=Mohney |first=Doug |date=September 26, 2011 |access-date=November 21, 2013 |archive-date=August 4, 2016 |archive-url=https://web.archive.org/web/20160804024136/http://satellite.tmcnet.com/topics/satellite/articles/222324-spacex-plans-test-reusable-suborbital-vtvl-rocket-texas.htm |url-status=live }}</ref> SpaceX built a {{Convert|0.5|acre|ha|adj=on}} concrete launch facility at its Rocket Development and Test Facility in [[McGregor, Texas]] to support the Grasshopper flight test program.<ref name="sfn20120709">{{cite news |url=http://www.spaceflightnow.com/news/n1207/10grasshopper/ |title=Reusable rocket prototype almost ready for first liftoff |newspaper=Spaceflight Now |first=Stephen |last=Clark |date=July 9, 2012 |access-date=July 13, 2012 |quote=SpaceX has constructed a half-acre concrete launch facility in McGregor, and the Grasshopper rocket is already standing on the pad, outfitted with four insect-like silver landing legs. |archive-date=May 21, 2013 |archive-url=https://web.archive.org/web/20130521132738/http://spaceflightnow.com/news/n1207/10grasshopper/ |url-status=live }}</ref>
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The DragonFly test vehicle is powered by eight [[SuperDraco]] engines, arranged in a redundant pattern to support [[fault-tolerance]] in the propulsion system design.<ref name=wt20140522/> SuperDracos use a [[storable propellant]] mixture of [[monomethyl hydrazine]] (MMH) [[fuel]] and [[nitrogen tetroxide]] [[oxidizer]] (NTO), the same propellants used in the smaller [[Draco (rocket engine family)|Draco]] thrusters used for [[Spacecraft attitude control|attitude control]] and [[Reaction control system|maneuvering]] on the first-generation [[Dragon spacecraft]].<ref name=faa201311/> While SuperDraco engines are capable of {{convert|16400|lbf|N|order=flip}} of thrust, during use on the DragonFly flight test vehicle, each will be [[Rocket engine throttling|throttled]] to less than {{convert|15325|lbf|N|order=flip}} to maintain vehicle stability.<ref name=faa201311/>
 
A test flight program of thirty flights was proposed in 2013–2014, including two ''propulsive assist'' (parachutes plus thrusters) and two ''propulsive landing'' (no parachutes) on flights dropped from a helicopter at an altitude of approximately {{convert|10000|ft|m|sp=us}}. The other 26 test flights were projected to take off from a [[launch pad]]: eight to be ''propulsive assist hops'' (landing with parachutes plus thrusters) and 18 to be ''full propulsive hops'', similar to the [[GrasshopperSpaceX (rocket)Grasshopper|Grasshopper]] and F9R Dev booster stage test flights.<ref name=faa201311/><ref name="wt20140522">{{cite news |last=Abbott |first=Joseph |date=May 22, 2014 |title=Grasshopper to DragonFly: SpaceX seeks approval for new McGregor testing |url=http://www.wacotrib.com/blogs/joe_science/grasshopper-to-dragonfly-spacex-seeks-approval-for-new-mcgregor-testing/article_11d0c40a-e1f6-11e3-a868-001a4bcf887a.html |url-status=live |archive-url=https://web.archive.org/web/20200606212803/https://www.wacotrib.com/blogs/joe_science/grasshopper-to-dragonfly-spacex-seeks-approval-for-new-mcgregor-testing/article_11d0c40a-e1f6-11e3-a868-001a4bcf887a.html |archive-date=June 6, 2020 |access-date=May 23, 2014 |newspaper=Waco Tribune |___location=Waco, Texas}}</ref> {{asof|2014}}, the DragonFly test program was not expected to start until after the completion of the [[F9R Dev1]] booster testing at the McGregor facility.<ref name=wt20140522/>{{update after|2014}}
 
=== Falcon 9 booster post-mission flight tests ===
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==== Landing attempts on drone ships ====
[[File:First stage of Jason-3 rocket (24423604506).jpg|thumb|First stage of [[Falcon 9 Flight 21]] descending over the floating landing platform, January 17, 2016, immediately prior to a soft touchdown followed by [[deflagration]] of the rocket after a landing leg failed to latch, causing the rocket to tip over.]][[Falcon 9 Flight 21]] launched the [[Jason-3]] satellite on January 17, 2016, and attempted to land on the [[autonomous spaceport drone ship|floating platform]] ''Just Read the Instructions'',<ref name=nbc20160107>{{cite news |url=http://www.nbcnews.com/tech/innovation/spacex-plans-drone-ship-rocket-landing-jan-17-launch-n492471 |title=SpaceX Plans Drone Ship Rocket Landing for Jan. 17 Launch |publisher=[[NBC News]] |first=Devin |last=Coldewey |date=January 7, 2016 |access-date=January 8, 2016 |archive-date=December 1, 2017 |archive-url=https://web.archive.org/web/20171201134820/http://www.nbcnews.com/tech/innovation/spacex-plans-drone-ship-rocket-landing-jan-17-launch-n492471 |url-status=live }}</ref> located for the first time about {{convert|200|mi|km}} out in the [[Pacific Ocean]].<!-- press conference, Hans Koenigsmann speaking for SpaceX: they are not attempting the landing on the land landing site at VAFB SLC4W because they have not yet received approval from the regulatory authorities; will find a secondary source before adding to the article prose... --><!-- HK: they may try to give video coverage of the landing, but unsure they can do it from over the horizon, satellite links, etc. --> Approximately 9 minutes into the flight, the live video feed from the drone ship went down due to the loss of its lock on the uplink satellite. The vehicle landed smoothly onto the vessel but one of the four landing legs failed to lock properly, reportedly due to ice from the heavy pre-launch [[fog]] preventing a lockout [[collet]] from latching.<ref name=sfn20160118>{{cite web |title=SpaceX narrowly misses booster landing at sea |work=Spaceflight Now |url=https://spaceflightnow.com/2016/01/18/spacex-narrowly-misses-booster-landing-at-sea/ |date=January 18, 2016 |access-date=January 18, 2016 |first=Stephen |last=Clark |archive-date=January 22, 2016 |archive-url=https://web.archive.org/web/20160122203126/http://spaceflightnow.com/2016/01/18/spacex-narrowly-misses-booster-landing-at-sea/ |url-status=live }}</ref> Consequently the booster fell over shortly after touchdown and was destroyed in a [[deflagration]] upon impact with the pad.<ref name=gw20160117>{{cite news |last=Boyle |first=Alan |url=http://www.geekwire.com/2016/spacex-launches-jason-3-satellite-then-tries-landing-falcon-9-rocket-at-sea/ |title=SpaceX rocket launches satellite, but tips over during sea landing attempt |work=GeekWire |date=January 17, 2016 |access-date=January 18, 2016 |archive-date=January 30, 2016 |archive-url=https://web.archive.org/web/20160130022126/http://www.geekwire.com/2016/spacex-launches-jason-3-satellite-then-tries-landing-falcon-9-rocket-at-sea/ |url-status=live }}</ref><ref name=rud>{{cite web |url=https://www.instagram.com/p/BAqirNbwEc0/ |title=Flight 21 landing and breaking a leg |work=Instagram |first=Elon |last=Musk |author-link=Elon Musk |date=January 17, 2016 |access-date=June 5, 2016 |archive-date=December 11, 2017 |archive-url=https://web.archive.org/web/20171211231212/https://www.instagram.com/p/BAqirNbwEc0/ |url-status=live }}</ref>
 
[[Falcon 9 Flight 22|Flight 22]] was carrying a heavy payload of {{convert|5271|kg|sigfig=2}} to [[geostationary transfer orbit]] (GTO). This was heavier than the previously advertised maximum lift capacity to GTO being made possible by going slightly [[subsynchronous orbit|subsynchronous]]. Following delays caused by failure of [[Falcon 9 Flight 19|Flight 19]], SpaceX agreed to provide extra thrust to the [[SES-9]] satellite to take it [[supersynchronous orbit|supersynchronous]].<ref name="sfn20160224">{{cite news |last=Clark |first=Stephen |date=February 24, 2016 |title=Falcon 9 rocket to give SES 9 telecom satellite an extra boost |url=http://spaceflightnow.com/2016/02/24/falcon-9-rocket-to-give-ses-9-telecom-satellite-an-extra-boost/ |url-status=live |archive-url=https://web.archive.org/web/20160305104120/http://spaceflightnow.com/2016/02/24/falcon-9-rocket-to-give-ses-9-telecom-satellite-an-extra-boost/ |archive-date=March 5, 2016 |access-date=March 7, 2016 |work=Spaceflight Now |quote=''SES’s contract with SpaceX called for the rocket to deploy SES 9 into a "sub-synchronous" transfer orbit with an apogee around 16,155 miles (26,000 kilometers) in altitude. Such an orbit would require SES 9 to consume its own fuel to reach a circular 22,300-mile-high perch, a trek that Halliwell said was supposed to last 93 days. The change [SpaceX offered] in the Falcon 9’s launch profile will put SES 9 into an initial orbit with an apogee approximately 24,419 miles (39,300 kilometers) above Earth, a low point 180 miles (290 kilometers) up, and a track tilted about 28 degrees to the equator.''}}</ref> As a result of these factors, there was little propellant left to execute a full reentry and landing test with normal margins. Consequently the Falcon 9 first stage followed a [[ballistic trajectory]] after separation and re-entered the atmosphere at high velocity, making it less likely to land successfully.<ref name=sxPressKit20160223>{{cite web |url=http://www.spacex.com/sites/spacex/files/spacex_ses9_press_kit_final.pdf |title=SES-9 Mission |work=Press Kit |publisher=SpaceX |date=February 23, 2016 |access-date=February 24, 2016 |quote=This mission is going to a Geostationary Transfer Orbit. Following stage separation, the first stage of the Falcon 9 will attempt an experimental landing on the "Of Course I Still Love You" droneship. Given this mission’s unique GTO profile, a successful landing is not expected. |archive-date=July 27, 2019 |archive-url=https://web.archive.org/web/20190727151524/https://www.spacex.com/sites/spacex/files/spacex_ses9_press_kit_final.pdf |url-status=live }}</ref><ref name=sfn20160224/> The [[atmospheric re-entry]] and controlled descent were successful despite the higher aerodynamical constraints on the first stage due to extra speed. However the rocket was moving too fast and was destroyed when it collided with the drone ship. SpaceX collected valuable data on the extended flight envelope required to recover boosters from GTO missions.
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====Falcon Heavy reusability====
The [[Falcon Heavy test flight]] had no contracted customer, and in order to limit the cost on such a flight, SpaceX targeted to have reused side-boosters. Boosters B1023 and B1025 that had been flown as a Falcon 9 configuration, were reconfigured and used as side boosters on the first flight of Falcon Heavy in February 2018, and then both landed side-by-side at almost the same time on the ground pads. Later Falcon Heavy flights used either new boosters, or side-boosters previously flown on a Falcon Heavy. SpaceX has been unable to recover the central core in any of the first three Falcon Heavy flights, but managed to recover all six side boosters.<ref>{{Cite web|url=https://www.theverge.com/2019/6/25/18743998/spacex-falcon-heavy-center-core-crash|title=SpaceX loses Falcon Heavy's center core in an otherwise successful launch|date=June 25, 2019|access-date=May 29, 2021|archive-date=February 8, 2021|archive-url=https://web.archive.org/web/20210208115526/https://www.theverge.com/2019/6/25/18743998/spacex-falcon-heavy-center-core-crash|url-status=live}}</ref>
 
==== Block 5 boosters ====
{{main|Falcon 9 Block 5}}
With a streak of 19 successful recovery attempts of the first stage from 2016 through to early 2018, SpaceX has focused on rapid reusability of first stage boosters. Block 3 and Block 4 proved economically feasible to be flown twice, as 11 such boosters have been reflown in 2017 and 2018. [[Falcon 9 Full Thrust Block 5|Block 5]] has been designed with multiple reuses in mind, up to 10 reuses with minimal inspection and up to 100 uses with refurbishment.<ref>{{Cite web |last=Seemangal |first=Robin |date=2018-05-04 |title=SpaceX Test-Fires New Falcon 9 Block 5 Rocket Ahead of Maiden Flight (Updated) |url=https://www.popularmechanics.com/space/rockets/a20152543/spacex-test-fire-new-falcon-9-block-5/ |access-date=2024-05-10 |website=Popular Mechanics |language=en-US}}</ref> New aggressive reentry profiles were experimented with expendable Block 3 and Block 4 boosters in early 2018, to test out the limitations on the range of recoverable launch margins that are potential for future Block 5.<ref>{{cite web|url=https://www.teslarati.com/spacex-old-gen-falcon-9-ready-rapid-reuse-block-5-rocket/|title=SpaceX expends "old-gen" Falcon 9 to ready for upcoming rapid reuse rocket|website=www.teslarati.com|date=April 3, 2018 |access-date=April 6, 2018|archive-date=April 7, 2018|archive-url=https://web.archive.org/web/20180407053456/https://www.teslarati.com/spacex-old-gen-falcon-9-ready-rapid-reuse-block-5-rocket/|url-status=live}}</ref> On 9 May 2021, [[List of Falcon 9 first-stage boosters#B1051|B1051]] became the first booster to be launched and landed for the tenth time, achieving one of SpaceX's milestone goals for reuse.<ref>{{cite web|title=SpaceX flies historic 10th mission of a Falcon 9 as Starlink constellation expands|url=https://www.nasaspaceflight.com/2021/05/historic-10th-falcon9-reflight/|website=NASASpaceFlight|access-date=9 May 2021|date=9 May 2021|archive-date=May 16, 2021|archive-url=https://web.archive.org/web/20210516121203/https://www.nasaspaceflight.com/2021/05/historic-10th-falcon9-reflight/|url-status=live}}</ref> {{As of|20242025|AprilJune}} the reuse record is 2028 flights.
 
=== Fairing reuse ===
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By April 2021, SpaceX had abandoned the experimental program to attempt recovery of dry payload fairings under [[parachute descent]] in a net on a [[platform supply vessel|fast ship]]. SpaceX decided to operationalize "wet recovery" of fairings on future Falcon 9 flights, having found that they can clean, refurbish, and reuse such fairings more economically.<ref name="ars20210409">{{cite news |last=Berger |first=Eric |date=9 April 2021 |title=Rocket Report: SpaceX abandons catching fairings |url=https://arstechnica.com/science/2021/04/rocket-report-spacex-abandons-catching-fairings-ula-bets-on-upper-stages/ |url-status=live |archive-url=https://web.archive.org/web/20210420105824/https://arstechnica.com/science/2021/04/rocket-report-spacex-abandons-catching-fairings-ula-bets-on-upper-stages/ |archive-date=April 20, 2021 |access-date=28 April 2021 |work=[[Ars Technica]]}}</ref> SpaceX released ''Miss Tree'' and ''Miss Chief'' from their contracts and purchased two ships for fairing recovery operations as well as for towing and supporting [[Autonomous spaceport drone ship|droneships]] on the east coast. These two ships were named in honour of [[Demo-2]] astronauts [[Doug Hurley]] and [[Bob Behnken]] as ''Doug''<ref>{{Cite web |title=DOUG (Offshore Supply Ship) Registered in USA – Vessel details, Current position and Voyage information – IMO 9529889, MMSI 368485000, Call Sign WDF2598 |url=https://www.marinetraffic.com/en/ais/details/ships/shipid:454774/mmsi:368485000/imo:9529889/vessel:DOUG |access-date=2021-08-25 |website=www.marinetraffic.com |language=en}}</ref> and ''Bob''. The earlier names of the ships Bob and Doug were Ella G and Ingrid respectively. Currently, Doug is operating at Port Canaveral while Bob is at Tampa undergoing construction.
 
By 26 May 2021, SpaceX had launched 40 flights that reflew at least one previously-flown fairing half, and one fairing had flown on five different flights, having been recovered and cleaned four previous times. As of now, SN152 is the oldest active fairing half still in use, while SN185 is the most flown (32 flights) active fairing half. On the other hand SN168 is the oldest, most-flown (28 flights) passive fairing half.<ref name=sn20210526>{{cite news |title=SpaceX sets Falcon 9 fairing reuse mark with Starlink launch |url=https://spacenews.com/spacex-sets-falcon-9-fairing-reuse-mark-with-starlink-launch/ |work=[[SpaceNews]] |last=Foust|first=Jeff |date=26 May 2021 |access-date=28 May 2021}}</ref>
 
=== Second-stage reuse ===
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The Starship is planned to replace all existing SpaceX launch and space vehicles after the mid-2020s: [[Falcon 9]], [[Falcon Heavy]] and the [[Dragon spacecraft]], aimed initially at the Earth-orbit [[Space launch market competition|launch market]] but with capability to support [[Beyond Earth orbit|long-duration spaceflight]] in the [[cislunar]] and [[Exploration of Mars|Mars mission]] environments.<ref name=musk20170929>
{{cite AV media | url=https://www.youtube.com/watch?v=tdUX3ypDVwI | people=Elon Musk | title=Becoming a Multiplanet Species |date=29 September 2017 |medium=video | ___location=68th annual meeting of the International Astronautical Congress in Adelaide, Australia | publisher=SpaceX | via=YouTube | access-date=8 March 2018}}</ref> Both stages will be fully reusable. The integrated [[secondMultistage stagerocket|second-stage]]-with-[[Spacecraft|spaceship]] design has not been used in previous launch vehicles.<ref name=musk20170929/>
 
=== Reuse of Dragon capsules ===
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{{Portal|Spaceflight}}
* [[New Shepard]], a sub-orbital VTVL system
* [[SpaceX Grasshopper|Grasshopper]]
* [[Grasshopper (rocket)]]
 
==Notes==