SpaceX gets US approval to test new Starfall capsules for space manufacturing

The Federal Aviation Administration (FAA) approved SpaceX’s Starfall reentry vehicle test flights on May 15, enabling two orbital missions before splashdowns in the Pacific Ocean, roughly 1,300 kilometers off California’s coast. The capsules, measuring 3.1 meters in diameter and 0.75 meters tall, will launch atop either a Falcon 9 or Starship rocket, with a direct suborbital trajectory as an option. Each capsule weighs 2,100 kilograms and can carry up to 1,000 kilograms of payload in a volume of 2.5 by 1.5 by 0.5 meters, using cold-gas thrusters and a single main parachute for recovery. The FAA’s environmental assessment, released May 29, outlines plans for Starfall to support in-space manufacturing and rapid point-to-point cargo delivery, aligning with SpaceX’s earlier military cargo contracts. The capsules could serve as a scalable alternative to the International Space Station (ISS) by providing microgravity and vacuum access, orbital loitering, and safe reentry services. SpaceX aims to develop a mass-producible vehicle compatible with both Falcon 9 and Starship, though no launch dates have been confirmed. Starfall’s design includes a heat shield jettisoned before splashdown and recovery by SpaceX teams via boats. The project may disrupt existing space manufacturing models, as competitors like Varda Space Industries currently rely on Falcon 9 rideshare missions. The FAA documents highlight SpaceX’s ambition to create a self-sustaining commercial manufacturing economy in space, though details remain limited pending official announcements. No specific launch timeline was provided, but the FAA emphasized Starfall’s potential as a large-scale initiative. The capsules’ precision delivery capabilities could expand SpaceX’s role in both commercial and military logistics, positioning the company as a key player in the evolving space economy.