Until recently, the idea of launching the same rocket into space multiple times in a single weekend seemed like something straight out of science fiction. However, everything changed on June 4, 2010, with the inaugural launch of SpaceX’s Falcon 9. Since then, the company has continuously made history in the space industry. What’s more, this year, it’s remained unchallenged by any competitors.
Recent milestones. According to Ars Technica, SpaceX recently reached a new level of efficiency with its Falcon 9, achieving 400 successful missions and 375 booster recoveries to date.
In November, the company set a record for rapid reusability by launching a booster just 13 days and 12 hours after its last landing, beating the previous record of 21 days. Additionally, SpaceX completed 16 Falcon 9 launches in a single month, which included Starlink missions and satellite deployments for the Department of Defense.
However, there’s much more to this story.
Unprecedented pace. In 2024, SpaceX has achieved an astonishing 119 Falcon 9 launches, averaging one launch every 2.3 days. If it meets its goal of 15 additional launches in December, the total for the year could reach 134 missions.
This isn’t just statistics. Including two Falcon Heavy missions would bring the total to 136 launches, surpassing the 135 flights made by NASA’s Space Shuttle program during its 30 years of operation. In other words, Falcon 9 has achieved in a single year what an entire space agency program accomplished over its lifetime.
The secret of reuse. The Falcon 9 rocket fulfills the main objective of SpaceX’s program: rapid and low-cost reusability. While there’s much more to discuss, one fact stands out.
A NASA Space Shuttle mission used to cost approximately $1.5 billion. In comparison, each Falcon 9 launch has an estimated internal marginal cost of only $15 million. This means that SpaceX operates at a flight rate 30 times higher than that of the Space Shuttle, at just one-hundredth of the cost.
Naturally, this level of efficiency would’ve been impossible without years of financial support from NASA. The space agency has contributed significantly, providing $400 million for the development of Falcon 9 and Dragon. NASA and SpaceX have also signed contracts for cargo missions, astronaut transport, and crewed missions (up to six to the International Space Station on SpaceX’s Crew Dragon).
The refurbishment process. Part of Falcon 9’s success is due to the effective refurbishment of its boosters. SpaceX CEO Elon Musk explained this process in an interview with Aviation Week a few years ago. The refurbishment includes detailed inspections, like X-raying the propellant tanks. Engineers also clean the landing legs and sweep the Merlin engines, which are necessary because kerosene is used as fuel.
Musk pointed out that this refurbishment process is relatively straightforward, with costs as low as $250,000 per booster. Most engines and components remain intact between flights, with only a few parts, such as turbines, occasionally needing replacement.
Costs and economic efficiency. Musk also explained how the $15 million marginal cost per launch is divided. Of this, $10 million is allocated directly to manufacturing a new second stage, which can’t be reused and must be produced for each launch. The remaining $5 million covers associated costs such as propellant, component recovery, and refurbishment.
Importantly, Musk revealed that SpaceX charges $50 million for a reused launch, a figure that has increased over time. This generates a substantial profit margin that funds projects like Starlink, which is expected to be a significant revenue source, and Starship. Additionally, SpaceX achieves considerable savings by reusing its boosters.
For instance, two consecutive launches of a reused Falcon 9 can generate approximately $110 million in revenue while incurring total costs of $65 million. This results in about $47 million in net profit. If a booster performs 10 launches, the estimated total costs would be $210 million, allowing SpaceX to conduct some flights for internal missions, like Starlink, at virtually “no cost.”
Industry comparison. As a result, SpaceX has achieved something unprecedented in the industry. It currently has no rivals capable of routinely recovering and reusing rockets. In fact, many competitors are still trying to develop their “own” Falcon 9.
According to the data, SpaceX has completed more launches in 2024 than its competitors over extended periods. It’s matched Roscosmos’ launch record since 2013, United Launch Alliance’s since 2010, and Arianespace’s since 2009. Moreover, in 2024 alone, Falcon 9 has flown more times than other flagship rockets, including Ariane 4, Ariane 5, and Atlas V, have in their entire history.
Challenges. Despite its success, SpaceX has faced setbacks. In July, a failure in the second stage led to the loss of 20 Starlink satellites, marking Falcon 9’s first major issue since 2016. In August, a booster failed to land after catching fire during its attempt, despite being on its 23rd flight, a record for reusability. Another booster matched this record in November and is expected to complete its 24th mission by the end of 2024.
Overall, Falcon 9 and its successors have achieved an unparalleled trajectory, redefining reusability and efficiency standards in the aerospace industry. They’ve demonstrated SpaceX’s ability to reach historic milestones at an unprecedented pace. The company’s low-cost, high-frequency launch model is transforming space exploration and laying the groundwork for a new era of access to space, potentially paving the way for a long-awaited arrival on Mars.
Image | Kelly Michals | Visual Capitalist
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