Looking ahead: Starship reflects on a remarkable year and anticipates a thrilling future in 2023

In 2023, SpaceX’s Starship Program experienced its most successful year yet, marked by significant achievements and developments. From multiple full stack flights to major updates in various areas of the program, SpaceX has made significant progress in optimizing Starship production and maintenance.

One notable area of progress is the shipyard, where several changes have occurred. SpaceX began constructing the second Mega Bay, also known as Ship Bay, which will replace the High Bay for ship construction. This new bay features a turntable for stacking vehicles and three work platforms for engine installation and separate work on boosters and ships. The first ship to utilize the new Ship Bay for engine installation is Ship 29.

Moreover, SpaceX upgraded the bridge cranes inside Mega Bay 1, enabling the lifting of boosters without engines using only one crane. However, when fully fitted with engines and shielding, both cranes are required for lifting boosters. With these advancements, SpaceX’s production of ships and boosters will significantly increase, allowing for more testing and flights to fulfill its contract for the Human Landing System for NASA’s Artemis Moon program.

At the Shipyard’s Starfactory, progress has been made with the demolition of the Windbreak, Midbay, and Tent 1 and 2 structures. With the completion of these demolition works, the factory will be approximately 800,000 square feet in size, with Tent 3 still needing to be demolished. Notable features of Starfactory include a press pit for hydraulic press operations and a section designated for nosecone construction.

Another area of focus for SpaceX is the Sanchez Site, which underwent a high number of changes in 2023. Initially housing the propellant production plant, Sanchez became the site for prefabricating sections of the new High Bay. Moreover, SpaceX relocated the Ground Support Equipment (GSE) building to the western corner of Sanchez and upgraded it with insulation for better work and welding environments. Construction also began on new white and black rings, serving as work stands and transport stands for boosters, respectively.

SpaceX’s activities in the Sanchez Site also involved the installation of a ship engine install stand near the Rocket Garden to simplify engine installation. However, this stand’s functionality may be taken over by the Ship Bay in the future. Additionally, preparations are underway at Sanchez to receive completed tower sections for the second Launch Pad at Starbase.

In terms of testing, SpaceX achieved several significant milestones. Cryo-proof tests were conducted on Ship 25 and boosters, starting with Booster 10. These tests involved the transportation of ships or boosters from the Shipyard to Masseys, where cryo and structural load tests were performed before returning them. Groundwork and the addition of subcoolers have been observed at Masseys, although the purpose of these developments remains unknown.

A major focus at the Launch Site was the completion of the Orbital Launch Mount’s shielding and the subsequent redesign of the pad’s foundation after the first flight resulted in significant damage. This redesign involved reinforcing the foundation with concrete and steel pilings, as well as the installation of a water-cooled steel plate flame deflector to protect against exhaust plume damage. The Launch Site’s Orbital Tank Farm was also upgraded to accommodate additional tanks and improve tanking and de-tanking efficiency.

Several flight tests were conducted throughout the year, highlighting both successes and challenges. The first flight test encountered issues such as a fire in Booster 7’s engine bay and problems with the Flight Termination Systems (FTS). Subsequent upgrades were implemented to avoid engine bay fires and improve the FTS. The second flight test saw improved performance until an unknown issue triggered the FTS, resulting in vehicle destruction.

The Starship program also achieved successful static fires and conducted single-engine static fires under flight-like conditions to simulate de-orbit burns. Currently, Ship 28 and Booster 10 are being prepared for launch, marking the end of the year on a high note for the Starship program.

Looking to the future, SpaceX’s plans for a Starship pad in Florida remain uncertain as the focus shifts to Starbase and system optimization. Nevertheless, SpaceX has ambitions to expand its Starship capabilities, potentially through additional facilities similar to the Roberts Road facility.

In 2024, SpaceX has several full stacks in various stages of assembly and testing, which could lead to as many as five launches. With flawless or nearly flawless launches, SpaceX aims to increase Starship’s cadence significantly. The Starship program is poised for an exciting future filled with continued milestones and advancements.