The SpaceX Archive
June 2, 2009 Wired.com

Space 2.X: The Private Rocket Race Takes Off

By Dave Bullock

HAWTHORNE, California — Building a successful startup in Silicon Valley is hard, but it’s not rocket science. Unless you’re SpaceX.

Eschewing the traditional startup trappings of two college grads eating ramen, watching Adult Swim and coding until the wee hours of the night, SpaceX instead employs hundreds of brainiacs and builds its rockets in a massive hangar that once housed a 747 fuselage factory.

Started in 2002 by PayPal founder Elon Musk, SpaceX (short for Space Exploration Technologies Corporation) brings a startup mentality to launching rockets into orbit, which until recently was almost exclusively government turf. The hope is that minimal bureaucracy, innovation and in-house manufacturing and testing can be used to put payloads into space at roughly one-tenth the cost of traditional methods.

If the company’s newest rocket, the Falcon 9, successfully completes its two scheduled launches this year, it will rendezvous with the International Space Station in 2010. After that, it will officially begin its mission as NASA’s Commercial Orbital Transportation Services platform, replacing the space shuttle as the method for transporting cargo and crew to the ISS.

SpaceX launched its first rocket, the Falcon 1, last September, placing a dummy payload into orbit. Space enthusiasts are holding their breath to see how Falcon 9 performs.

Here’s a behind-the-scenes look at SpaceX’s facility. This is how the private sector builds a rocket capable of space travel.

Looking less like a lab full of rocket scientists and more like Google, SpaceX foregoes offices and private meeting rooms. Instead the company opts for an open floor plan and glass-paneled conference rooms. Don’t be fooled, those are rocket scientists. Dave Bullock/Wired.com
Left: SpaceX uses a high-tech, strong and lightweight aluminum-lithium alloy with a rigid internal structure in the construction of its Falcon 1 rocket. The lighter the rocket, the heavier the payload can be. Right: An extremely accurate laser survey device, left, is used to ensure that rocket parts fall within SpaceX’s tight tolerances. Dave Bullock/Wired.com
Left: High-pressure, high-temperature manifolds and final rocket cones wait for assembly into rocket engines. Right: The business end of a Falcon 1 rocket stage fuel tank stands nearly ready to be mated with a rocket motor and blasted into space. Dave Bullock/Wired.com
Left: Machinists in the SpaceX shop use computerized mills and lathes to form raw chunks of exotic alloys into working rocket parts. Right: A rocket motor is being formed in a milling machine. The hoses hanging from the door are used to lubricate the bit and wash away slivers of metal the mill removes. Dave Bullock/Wired.com