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In December twenty fifteen, SpaceX landed
an orbital Falcon nine rocket booster back on

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the Earth for the first time in
the history of human spaceflight, and in

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the eight years since, SpaceX remains
the only rocket provider who can accomplish this

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feat. In fact, no one
else has even tried. So what's the

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deal with that? How did SpaceX
come out of nowhere and leap frog over

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companies that had already been launching rockets
for decades. Could it be that Elon

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Musk is an unprecedented super mega techno
genius. Yeah, maybe, But we

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think that there's a much more fascinating
and satisfying answer to be found here,

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So let's get into it. This
is the space race. If there is

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one defining factor that sets SpaceX apart
from the rest of the aerospace industry,

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it is the reusable rocket. SpaceX
has completely reinvented this technology in a way

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that no one has ever dared to
dream. But that's not entirely true,

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is it. Obviously someone down the
line must have had the thought that maybe

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it would be better to try and
keep these gigantic rocket boosters instead of just

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sending them to the bottom of the
ocean every time. And we all know

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that the Space Shuttle was already reusable. Right, Even Blue Origin can land

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their rocket booster the same as a
Falcon nine. If you ask other leaders

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in the aerospace industry, they'll try
to tell you that reusable rockets are not

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actually any more economical or sustainable than
the traditional method, and that landing a

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booster is more of a parlor trick
than an innovation. So what is it

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that really sets SpaceX apart? Then? To find the answer, we have

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to go back to the beginning.
The first rocket boosters to ever send a

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payload into outer space were simply reconfigured
intercontinental ballistic missiles. The Titan two,

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which served as the launched booster for
NASA's Project Gemini, was originally designed to

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send a nine megaton nuclear warhead halfway
around the world. So there's only so

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much and realistically expect them to do. When it came time for the Apollo

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missions to the Moon, NASA was
ready to design their first bespoke orbital rocket,

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the Saturn five. It was a
humongous vehicle that to this day still

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dwarfs nearly every rocket ever produced,
and yet only the relatively tiny crew capsule

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at the very top ever returned to
the Earth. The rest was either dumped

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in the ocean, left floating in
space, or abandoned on the surface of

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the Moon. This seems like a
waste of money and resources, but in

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reality, it was the preferred option
for NASA to make the Saturn five entirely

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disposable. This was the most economic
choice at the time because the Saturn five

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was only ever intended to fly around
a dozen missions, and it was calculated

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that the cost to build twelve disposable
rockets would still be cheaper than developing just

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one reusable rocket. Besides, the
engineers at NASA were already looking towards the

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future even before the first person set
foot on the Moon. NASA was developing

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their space Shuttle concept, a fully
reusable rocket plane and booster system that would

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be the true answer to sustainable human
spaceflight. NASA's chief architect of the Saturn

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five, Werner von Braun, perfected
his concept for the Faery rocket back in

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the mid nineteen fifties. The former
Nazi rocket scientist would come to be known

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in America as the father of space
travel. We didn't really find out about

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the Nazi thing until after he was
dead, so we can only appreciate how

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screwed up this was in hindsight.
Anyway, the Faery Rocket was going to

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be the vehicle that brought human space
flight to the main stream. The three

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stage rocket would be fully reusable,
with the two first booster cores coming down

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softly on parachutes and the third stage
orbiter gliding back to Earth for a runway

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landing. We should probably do a
full video someday just on the Fairy rocket

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concept alone. What do you think? Let us know in the comments below.

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Anyway, you'll notice that this all
sounds pretty similar to what the Space

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Shuttle ended up being, yet still
quite di frint in the fundamental design.

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While the Space Shuttle has generally been
built as a reusable space plane, the

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more correct terminology is generally considered to
be refurbishable. But what's the difference.

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If you go to an airport,
you can watch a plane land, unload

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its passengers and cargo, then get
rapidly cleaned, restocked, and refueled before

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taking on a load of passengers and
lifting off into the sky. Yet again,

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that all happens within the span of
about an hour or maybe even less,

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so we can safely say that a
commercial airplane is reusable. Now if

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that same airplane had to be fully
disassembled, inspected, serviced, and put

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back together after every single flight,
does that still fit the same definition of

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reusable. Not so much, and
it certainly doesn't sound like a sustainable way

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to operate a commercial airline. That
is the issue that NASA faced with their

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Space Shuttle. It could technically be
reused, which fit the initial criteria that

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the agency was granted by US Congress
when Shuttle was funded back in nineteen seventy

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two, but the procedure involved to
actually get a Space Shuttle and its twin

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booster engines back on the launch pad
after being flown just one time ended up

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totaling around six hundred and fifty thousand
hours of combined labor spent on transporting and

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refurbishing the system. Obviously that all
happened simultaneously, not sequentially, Otherwise it

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would take seventy four years to refurbish
one Space Shuttle. The thing about reusable

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rockets is that they are only valuable
if the frequency of launches is great enough

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to outweigh the cost of developing and
utilizing the technology. So, like we

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were saying, before. This is
how NASA decided it was cheaper to launch

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twelve disposable rockets instead of developing one
reusable system. And at what point does

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a reusable rocket actually start to make
sense economically? How many launches does that

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take? NASA never really had the
chance to find out. Not only did

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the Space Shuttle need more work to
refurbish than had been expected, it never

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flew anywhere near as frequently as NASA
envisioned either. In the end, it

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would have been cheaper or at least
just as expensive for NASA to throw every

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Space Shuttle in the garbage after one
flight and build a whole new one.

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So, if you want a good
answer as to why none of the commercial

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rocket companies ever tried to develop their
own reusable vehicle, it's because they already

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saw what happened with the Space Shuttle, not only the most expensive rocket ever

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developed, but also the most dangerous
and probably the least successful at fulfilling its

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original design concept. And if NASA
couldn't do it, then obviously no one

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else would even stand a chance.
Right then along came SpaceX, who decided

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that they will succeed where all others
have failed. Now, to be fair,

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SpaceX did come at the problem from
a much different angle than NASA had

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taken with the Shuttle, and in
many ways their approach with the Falcon nine

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does make a lot more sense from
a logistics standpoint. Something that SpaceX had

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envisioned from the very start of their
development with a Falcon one rocket was recovering

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and reusing both the first stage booster
and the upper stage vehicle by having them

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execute a propulsive return to launch site
and landing maneuver. Now, they gave

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up on recovering the second stage pretty
early on, and that's a reasonable concession

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to make, because with a conventional
rocket, the upper stages a relatively simple

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vehicle that consists of just one engine, a couple of small fuel tanks,

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and a platform that holds the payload
until it's time to deploy. But recovering

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the first stage booster is a much
more valuable proposition as long as you can

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make that booster fully reusable, not
just refurbishable, and then fly it often

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enough to make the extra effort worthwhile. Of course, SpaceX opted for the

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most technically challenging recovery method there is, the propulsive landing. This was unprecedented

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territory back in Werner von Bron's old
ferry rocket concept. The booster stages would

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fire their engines on the return to
Earth as a way to help slow them

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down, but ultimately would land in
the ocean water under giant parachutes. And

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NASA had successfully recovered the Space shuttles
twin booster engines by simply parachuting them back

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down following stage separation. So why
didn't SpaceX use parachutes on their Falcon booster

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Short answer, they tried, but
physics wouldn't allow it. Parachuting the shuttle

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boosters worked for two reasons. One, they were pretty small and pretty light,

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being solid rocket boosters. Once all
of the propellant is burnt up,

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they're basically just empty metal tubes.
Two, the shuttle boosters separated at a

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relatively low altitude and therefore a relatively
low velocity of just around forty eight hundred

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kilometers per hour. They were only
really necessary to get the shuttle off the

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ground and through the thickest part of
the atmosphere. After that, the shuttle

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still had three incredibly powerful hydrogen burning
RS twenty five engines that continue pushing to

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reach orbital velocity in a single core
two stage rocket like the Falcon nine,

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that one booster has to impart a
tremendous amount of velocity into the upper stage

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so that the final vacuum engine can
continue to accelerate the payload into orbit.

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This means the Falcon booster will fly
much higher and faster, reaching a speed

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over eight thousand kilometers per hour at
stage separation. The formula for kinetic energy

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is one half mass times velocity squared, which, in the case of a

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Falcon nine booster that just released an
orbital payload, equals way too much energy

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for any parachute to withstand. That
is why von Braun envisioned the hybrid of

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engine d acceleration combined with parachute assisted
landing. But this is Elon Musk philosophy

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we're talking about now, and the
best part is no part. The rocket

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already has engines, so why bother
adding parachutes to lower velocity when the engines

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can do the exact same thing.
The engines on the Falcon nine also serve

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a dual purpose as a free heat
shield to protect the booster as it re

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enters the atmosphere. So in the
case of a drone ship land ending scenario,

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the Falcon nine booster is going to
coast up and clear through the atmosphere,

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crossing over the carbon line and technically
being in space for about a minute

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or so. But since it's not
traveling at orbital velocity, the booster is

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eventually going to fall back down.
As this begins to happen, the booster

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is going to flip around and point
its engines in the opposite direction to perform

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a re entry burn. The maneuver
is going to start killing a ton of

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the booster's velocity, which is important, but even more critical, the thrust

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from the engines will create a force
field underneath the rocket that protects the metal

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from the extreme heat of reentry.
That's when you see the crazy jellyfish looking

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cloud of smoke and fire build up
underneath the rocket as it's coming back down.

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It looks awesome. Then the booster
will coast down through the atmosphere,

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losing more velocity to friction as it's
guided in by aerodynamic gridfins. At the

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last moment, the engines will reignite
one more time to make sure that the

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booster velocity reaches zero. At the
moment that the landing legs touched down on

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the floating platform. This is a
procedure that SpaceX has now repeated well over

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a hundred times, and these days
they make it look pretty easy, but

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that was not always the case.
It took SpaceX a lot of trial and

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error and multiple upgrade cycles to the
Falcon nine before they could truly stick the

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landing. Most people might not realize
that the Falcon nine was not a genuine

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reusable rocket until SpaceX achieved its final
form in twenty eighteen, known as the

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Block five. Most rockets don't really
go through an active development cycle once they

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begin operation. The design they have
on the first successful launch is more than

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likely going to be what they stick
with throughout the life cycle of the product,

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and that's because rockets are very temperamental
and dangerous vehicles. Anytime you change

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a design, you introduce an unknown
variable which could then in turn lead to

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a failure, and no one wants
that unless your SpaceX. Another of elon

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philosophy, if things are not failing, you are not innovating enough. Let's

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start with the Falcon nine Version one. The first iteration of this rocket was

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actually a lot smaller, at just
about forty six meters in total length and

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a lot less powerful at just one
point one million pounds of thrust. Even

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though SpaceX had already intended to make
falconine a reusable booster, this version didn't

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receive any of the necessary gridfins or
landing legs to make that possible. They

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wanted to make sure that it went
up properly before they thought too much about

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getting it back down. This Falcon
nine flew five missions, including one to

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send a cargo Dragon capsule to the
ISS. Next up is Falcon nine Version

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one point one. This variant grew
significantly to over sixty eight meters in length.

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It was the first to utilize the
Merlin one D engine and the circular

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octaweb engine layout. This increased the
total thrust to one point three million pounds

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total. That extracize and power made
this the first Falcon nine capable of a

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controlled return to Earth, because it
could get a payload into orbit with enough

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fuel left over to perform the necessary
re entry and landing burns. SpaceX began

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experimenting with this capability in small scale
tests, where they would attempt to bring

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the rocket down for soft landings over
the open ocean. It wasn't until the

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CRS three mission to resupply the ISS. In April twenty fourteen that the Falcon

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nine received its first set of landing
legs, and then for CRS five in

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January twenty fifteen, the first set
of gridfins were added to achieve more precise

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control when free falling through the atmosphere. This gave SpaceX the confidence to attempt

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their first ever drone ship landing on
that same flight. It didn't work,

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but they got surprisingly close for something
that was thought to be genuinely impossible at

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the time. None of the Version
one point one rockets ever successfully landed,

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and then in June twenty fifteen,
the Falcon nine experienced a mid air failure

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and broke apart. This gave SpaceX
enough pause to shut down operations until they

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were able to come back with another
revision to the booster design. Falcon nine

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Version one point two is also sometimes
referred to as Falcon nine Full thrust,

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just slightly longer, now reaching seventy
meters in length and getting a massive increase

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in power to one point seven million
pounds of thrust. Most of this power

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gain came from SpaceX cooling their liquid
oxygen and rocket fuel to lower temperatures,

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which increases their energy density. This
is where SpaceX really followed through on their

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promise to learn through failure, because
the first launch of the Falcon nine full

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thrust also marked the first successful landing
of an orbital rocket booster in the history

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of spaceflight, with the booster touching
down onto a SpaceX landing pad at Cape

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Canaveral. The full thrust went through
a series of small tweaks and variations over

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the years as SpaceX prepared to finalize
the rocket into its ultimate form. The

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reason that they had to do this
in order to get the Falcon nine crew

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raided by NASA. It's fine to
play around with variables when there is only

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money and equipment on the line,
but once it's agreed that a rocket is

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safe to carry human beings, then
you have to stop messing with it.

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So we arrive at the Falcon nine
Block five. It's the exact same size

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as the previous version and only slightly
more powerful at one point eight million pounds

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of total thrust. The most obvious
visual que to identify these variants is the

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black paint in the middle and on
the landing legs. The real upgrades here

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are being made to increase the overall
reusability of the rocket booster. Remember we

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talked about the difference between reusable and
refurbishable. The Falcon nine full thrust was

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refurbishable in some situations, but for
the most part SpaceX only recovered those boosters.

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They didn't reuse them very often.
The first SpaceX launched to use a

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refurbished Falcon nine happened in March twenty
seventeen, and it made use of a

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booster that had been recovered over one
year prior. As far as changes with

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the Block five, SpaceX upgraded the
turbopumps inside their Merlin engines when it was

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discovered that the units formed very small
micro cracks after being launched and recovered.

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The grid fins on the side of
the rocket were also made stronger with an

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upgrade from aluminum to titanium metal.
At the time, these fins were the

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largest single pieces of forged titanium ever
made and therefore incredibly expensive, but this

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gave them a much greater resistance to
the heat of reentry and greater control over

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the rocket's angle of attack as it
coasted through the air. The entire body

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of the Falcon nine was given a
thermal protective coating that reduced heat absorption across

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the entire rocket. In addition,
a new reusable and replaceable liquid cooled heat

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shield was added to the base of
the rocket for greater protection of the engines

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and plumbing system. The Block five
landing legs were upgraded to allow them to

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both extend and retract. The previous
legs actually couldn't fold back up after the

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rocket was recovered. They had to
be unbolted and removed. SpaceX also made

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an improvement to the cpovs on the
Block five. These are ultra high pressure

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tanks that are wrapped in carbon fiber. They are used to store helium gas

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that maintains pressure inside fuel tanks as
they empty. And a COPV failure was

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linked to both of the previous Falconine
explosions, one in air and one on

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the launchpad. It's been five years
now since SpaceX made all of those reusability

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upgrades to the Falcon nine, So
what do they have to show for it?

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Did they make a truly reusable rocket
earlier this summer? On July tenth,

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SpaceX successfully launched and landed Falcon nine
booster B one zero five eight for

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the sixteenth time. This is the
same booster that launched astronauts Dug Hurley and

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Bob Benkin to the International Space Station
in May twenty twenty, the first time

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a crew had ever flown on a
SpaceX rocket. So that's sixteen flights in

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just over three years. SpaceX had
a ridge only believe that the Falcon nine

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Block five would be good for up
to ten launches and landings, but that

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lifespan projection increased to fifteen launches in
twenty twenty two, and right now SpaceX

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has certified B one zero five eight
for up to twenty launches, and based

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on extended life vibration testing by SpaceX
engineers, they think that the Block five

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could withstand as many as sixty launches
and landings. For comparison, the Space

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Shuttle Discovery completed thirty nine missions,
more than any other Shuttle in the fleet.

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On average, there were only between
five and eight Space Shuttle launches in

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any given year, with one hundred
and thirty five total missions spread across thirty

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years and five vehicles, So that's
not a whole lot of precedent to work

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with, But according to the numbers
that we do have, yeah, the

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Falcon nine is an extremely reusable rocket. Booster, and a good one at

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that. So now all we have
left to do is sit and wait for

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the next leap forward to begin.
The Starship take reusable rockets to the next level.
