Reusable launch vehicle in the context of SpaceX reusable launch system development program


Reusable launch vehicle in the context of SpaceX reusable launch system development program

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⭐ Core Definition: Reusable launch vehicle

A reusable launch vehicle has parts that can be recovered and reflown, while carrying payloads from the surface to outer space. Rocket stages are the most common launch vehicle parts aimed for reuse. Smaller parts such as fairings, boosters or rocket engines can also be reused, though reusable spacecraft may be launched on top of an expendable launch vehicle. Reusable launch vehicles do not need to make these parts for each launch, therefore reducing its launch cost significantly. However, these benefits are diminished by the cost of recovery and refurbishment.

Reusable launch vehicles may contain additional avionics and propellant, making them heavier than their expendable counterparts. Reused parts may need to enter the atmosphere and navigate through it, so they are often equipped with heat shields, grid fins, and other flight control surfaces. By modifying their shape, spaceplanes can leverage aviation mechanics to aid in its recovery, such as gliding or lift. In the atmosphere, parachutes or retrorockets may also be needed to slow it down further. Reusable parts may also need specialized recovery facilities such as runways or autonomous spaceport drone ships. Some concepts rely on ground infrastructures such as mass drivers to accelerate the launch vehicle beforehand.

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👉 Reusable launch vehicle in the context of SpaceX reusable launch system development program

SpaceX has privately funded the development of orbital launch systems that can be reused many times, similar to the reusability of aircraft. SpaceX has developed technologies since the 2010s to facilitate full and rapid reuse of space launch vehicles. The project's long-term objectives include returning a launch vehicle 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 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. Development of reusable second stages for Falcon 9 was later abandoned in favor of developing Starship. However, SpaceX still developed reusable payload fairings for the Falcon 9.

The program was announced in 2011. SpaceX first achieved a successful landing and recovery of a first stage in December 2015. The first re-flight of a landed first stage occurred in March 2017 with the second occurring in June 2017, that one only five months after the maiden flight of the booster. 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.

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Reusable launch vehicle in the context of SpaceX

Space Exploration Technologies Corp., commonly known as SpaceX, is a private American aerospace company and space transportation company headquartered at the Starbase development site in Starbase, Texas. Since its founding in 2002, the company has made numerous advances in rocket propulsion, reusable launch vehicles, human spaceflight and satellite constellation technology. As of 2025, SpaceX is the world's dominant space launch provider, its launch cadence eclipsing all others, including private competitors and national programs like the Chinese space program. SpaceX, NASA, and the United States Armed Forces work closely together by means of governmental contracts.

SpaceX was founded by Elon Musk in 2002 with a vision of decreasing the costs of space launches, paving the way to a self-sustaining colony on Mars. In 2008, Falcon 1 successfully launched into orbit after three failed launch attempts. The company then moved towards the development of the larger Falcon 9 rocket and the Dragon 1 capsule to satisfy NASA's COTS contracts for deliveries to the International Space Station. By 2012, SpaceX finished all COTS test flights and began delivering Commercial Resupply Services missions to the International Space Station. Also around that time, SpaceX started developing hardware to make the Falcon 9 first stage reusable. The company demonstrated the first successful first-stage landing in 2015 and re-launch of the first stage in 2017. Falcon Heavy, built from three Falcon 9 boosters, first flew in 2018 after a more than decade-long development process. As of May 2025, the company's Falcon 9 rockets have landed and flown again more than 450 times, reaching 1–3 launches a week.

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Reusable launch vehicle in the context of Expendable launch system

An expendable launch system (or expendable launch vehicle/ELV) is a launch vehicle that can be launched only once, after which its components are destroyed during reentry or impact with Earth, or discarded in space. ELVs typically consist of several rocket stages that are discarded sequentially as their fuel is exhausted and the vehicle gains altitude and speed. As of 2024, fewer and fewer satellites and human spacecraft are launched on ELVs in favor of reusable launch vehicles. However, there are many instances where a ELV may still have a compelling use case over a reusable vehicle. ELVs are simpler in design than reusable launch systems and therefore may have a lower production cost. Furthermore, an ELV can use its entire fuel supply to accelerate its payload, offering greater payloads. ELVs are a proven technology in widespread use for many decades.

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Reusable launch vehicle in the context of Falcon Heavy

Falcon Heavy is a super heavy-lift launch vehicle with partial reusability that can carry cargo into Earth orbit and beyond. It is designed, manufactured and launched by American aerospace company SpaceX.

The rocket consists of a center core on which two Falcon 9 boosters are attached, and a second stage on top of the center core. Falcon Heavy has the second highest payload capacity of any currently operational launch vehicle behind NASA's Space Launch System (SLS), and the fourth-highest capacity of any rocket to reach orbit, trailing behind the SLS, Energia and the Saturn V.

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Reusable launch vehicle in the context of SpaceX Starbase

SpaceX Starbase, previously known as SpaceX South Texas Launch Site and SpaceX private launch site, is an industrial complex and rocket launch facility that serves as the main testing and production location for Starship launch vehicles, as well as the headquarters of the American space technology company SpaceX. Located in Starbase, Texas, United States, and adjacent to South Padre Island, Texas, Starbase has been under near-continuous development since the late 2010s, and comprises a spaceport near the Gulf of Mexico, a production facility, and a test site along Texas State Highway 4.

When initially conceptualized in the early 2010s, its stated purpose was "to provide SpaceX an exclusive launch site that would allow the company to accommodate its launch manifest and meet tight launch windows." The launch site was originally intended to support launches of the Falcon 9 and Falcon Heavy launch vehicles as well as "a variety of reusable suborbital launch vehicles". In early 2018, SpaceX announced a change of plans, stating that the launch site would now be used exclusively for SpaceX's next-generation launch vehicle, Starship. Between 2018 and 2020, the site added significant rocket production and test capacity. SpaceX Chief Executive Officer (CEO) Elon Musk indicated in 2014 that he expected "commercial astronauts, private astronauts, to be departing from South Texas," and eventually launching spacecraft to Mars from the site.

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Reusable launch vehicle in the context of SpaceX Starship

Starship is a two-stage, fully reusable, super heavy-lift launch vehicle under development by American aerospace company SpaceX. Currently built and launched from Starbase in Texas, it is intended as the successor to the company's Falcon 9 and Falcon Heavy rockets, and is part of SpaceX's broader reusable launch system development program. If completed as designed, Starship would be the first fully reusable orbital rocket and have the highest payload capacity of any launch vehicle to date. As of October 13, 2025, Starship has launched 11 times, with 6 successful flights and 5 failures.

The vehicle consists of two stages: the Super Heavy booster and the Starship spacecraft, both powered by Raptor engines burning liquid methane (the main component of natural gas) and liquid oxygen. Both stages are intended to return to the launch site and land vertically at the launch tower for potential reuse. Once in space, the Starship upper stage is intended to function as a standalone spacecraft capable of carrying crew and cargo. Missions beyond low Earth orbit would require multiple in-orbit refueling flights. At the end of its mission, Starship reenters the atmosphere using heat shield tiles similar to those of the Space Shuttle. SpaceX states that its goal is to reduce launch costs by both reusing and mass producing both stages.

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Reusable launch vehicle in the context of Flight test

Flight testing is a branch of aeronautical engineering that develops technologies and equipment required for in-flight evaluation of behaviour of an aircraft or launch vehicles and reusable spacecraft at the atmospheric phase of flight. Instrumentation systems for flight testing are developed using specialized transducers and data acquisition systems. Data is sampled during the flight of an aircraft, or atmospheric testing of spacecraft. This data is validated for accuracy and analyzed to further modify the vehicle design during development, or to validate the design of the vehicle.

The flight test phase accomplishes two major tasks: 1) finding and fixing aircraft design problems and then 2) verifying and documenting the vehicle capabilities when the vehicle design is complete, or to provide a final specification for government certification or customer acceptance. The flight test phase can range from the test of a single new system for an existing vehicle to the complete development and certification of a new aircraft, launch vehicle, or reusable spacecraft. Therefore, the duration of a particular flight test program can vary from a few weeks to years.

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