A Farewell To Hackaday’s Favorite Falcon 9 Booster

February 25, 2020 by 39 Comments

With the notable exception of the Space Shuttle, rockets and spacecraft have always been considered disposable. It’s a slow and expensive way to travel, akin to building a new airliner for every flight, but it was the easiest option. These vehicles have always represented the pinnacle of engineering and material science of their time, and just surviving the trip to space once was an incredible accomplishment. To have another go around would have been asking too much of the technology. Even looking back on the Space Shuttle program, there’s plenty of debate about whether or not the reusable design really paid off in the end.

So SpaceX’s ability to land, refurbish, and refly the first stage of their Falcon 9 booster is no small accomplishment. After demonstrating the idea was possible in 2017, the company made numerous changes to the latest iteration of the rocket with reusability in mind. Known as Block 5, this version of the Falcon 9 is designed to be more survivable and require minimal servicing between flights. The company says its cheaper and faster to reuse the Block 5 than it would be to build a new one for each flight, allowing the company to approach spaceflight more like commercial aviation.

Falcon 9 launch and landing streaks
Falcon 9 launch and landing streaks. (Source: SpaceX)

With a fleet of Block 5 boosters now in rotation, SpaceX has given them serial numbers not unlike an airplane’s tail number. It might not be the kind of thing the general public would normally be aware of, but these serial numbers have allowed a dedicated community of space aficionados to keep track of the missions each booster has flown.

Unfortunately the story of one of these rockets, officially referred to as “Cores” in SpaceX parlance, was recently cut short. Core B1056, returning from the Starlink 4 mission on February 17th, failed to land on the autonomous spaceport drone ship (ASDS) Of Course I Still Love You and splashed down in the ocean. It’s still unclear what condition the booster was in after its soft landing in the water, but when the recovery ships returned to port empty handed, there was no question as to the fate of B1056.

From a purely business standpoint, the failure of any of SpaceX’s boosters means lost time and revenue. But in some ways B1056 had established itself as the vanguard of the fleet, managing to either set or break a number of records in its relatively short life. The destruction of the most thoroughly flight proven Block 5 booster is a stark reminder that there’s very little about spaceflight that could be called routine.

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Deploy Workaround Code To The Field When “The Field” Is Lunar Orbit

February 3, 2020 by 6 Comments

The Apollo missions still inspire people today, decades after they took place. A fortunate side effect of the global public relations campaign is that a lot of information is publicly available for us to review and process. We’re right around the 49th anniversary of Apollo 14 mission, so it was a good time for [Frank O’Brien] to take readers through Apollo Guidance Computer and the hack that saved Apollo 14 (while it was in lunar orbit).

Space fans would already know many parts of this piece, but [Frank] weaves it together into a single narrative around a problematic “Abort” button that was found to be making intermittent contact as the crew were preparing to land on the moon. An inconvenient timing would have unnecessarily aborted the mission, which was obviously Not Good. [Frank] brings us up to speed on AGC fundamentals, just enough to understand the technical constraints for the hack, devised within the time constraints they faced.

For those that prefer a short video summary [Scott Manley] covered this same hack on YouTube. And for another perspective on the scope of this task, remember this was years before we had vi or emacs. When they were contemplating flipping status bits as programs were running, it’s not trivial to do a global search for code that might examine those bits. Look at the tome of source code AGC programmer [Don Eyles] worked with. Space fans who want to learn more can check out [Don]’s book.

For the ultimate AGC talk, check out The Ultimate AGC Talk.

Maybe someday trips to the moon will be a commonplace thing, but Apollo will always be the pioneer.

How Efficient Can An Airplane Be? The Celera 500L Sets To Find Out

January 22, 2020 by 83 Comments

One of the current hype trends is the supposedly imminent revolution in air transport. So many companies showing digital renderings and mockups to illustrate their own utopic vision for the future, reaching fevered pitch at events like CES 2020. But aviation has a long history of machinery that turned out to be impractical. Wouldn’t it be great if a company focused their resources on building real aircraft and get real data before cranking up their hype machine? The people at Otto Aviation thought so, and their Celera 500L has reportedly taken to the skies.

If you said “Otto who?” you are not alone. The company has zero PR activity to speak of. Limited internet attention started from aviation fans spotting the Celera 500L under construction at its Southern California airfield. Its unusual exterior appearance and proximity to Hollywood made some dismiss it at first as a movie prop. Anyone with a passing interest in aerospace engineering could immediately see aerodynamics was a priority in this design, its long thin unswept glider-like wings implies the goal is fuel efficiency rather than speed. This was confirmed by internet sleuths uncovering patents filed by people associated with the company.

The patents include very lofty fuel efficiency goals, and industry veterans are skeptical. Fuel is a huge factor in aircraft operating costs where small increases in efficiency translate to big dollars over a plane’s lifetime. It’s hard to believe every other plane maker would deliberately leave so much on the table. There must be far more to the 500L inside that teardrop shaped body, with innovations and potentially making some trade-offs no other company has made. We can see two of them from the outside: the 500L traded off some pilot visibility for aerodynamics, and it has very little ground clearance to absorb the impact of less-than-ideal landings.

It’s certainly possible the ideas leading to this plane will fail to pan out in reality like so many ideas before them. Aerospace engineering is a field littered with debris of concepts that looked great on paper but crashed against a hard and unforgiving reality. But at least Otto Aviation is trying something new by building real hardware to get real data, something well worth recognizing in a sea of hyped up fantasy renderings.

[Photo via SoCal Airshow Review]

2019: As The Hardware World Turns

December 27, 2019 by 31 Comments

Well, this is it. The end of the decade. In a few days the 2010s will be behind us, and a lot of very smug people will start making jokes on social media about how we’re back in the “Roaring 20s” again. Only this time around there’s a lot more plastic, and drastically less bathtub gin. It’s still unclear as to how much jazz will be involved.

Around this time we always say the same thing, but once again it bears repeating: it’s been a fantastic year for Hackaday. Of course, we had our usual honor of featuring literally thousands of incredible creations from the hacking and making community. But beyond that, we also bore witness to some fascinating tech trends, moments that could legitimately be called historic, and a fair number of blunders which won’t soon be forgotten. In fact, this year we’ve covered a wider breadth of topics than ever before, and judging by the record setting numbers we’ve seen in response, it seems you’ve been just as excited to read it as we were to write it.

To close out the year, let’s take a look at a few of the most popular and interesting stories of 2019. It’s been a wild ride, and we can’t wait to do it all over again in 2020.

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University Makes Bulletproof 3D Prints

November 20, 2019 by 68 Comments

Researchers at Rice University are studying 3D printing plastic structures that mimic tubulanes — theoretical nanotube structures predicted to have extraordinary strength. The result has been very strong and very compressible structures that can actually resist bullets.

As an experiment, the researchers fired projectiles at 5.8 km/s at a block of plastic and at a block of simulated tubulanes. The structure of the tubulane block stopped the bullet at the second layer with no significant structural damage beyond the second layer. The reference block had a large hole and cracks throughout its volume.

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Hacking Mars: InSight Mole Is On The Move Again

October 28, 2019 by 23 Comments

Your job might be tough, but spare a thought for any of the engineers involved in the Mars InSight lander mission when they learned that one of the flagship instruments aboard the lander, indeed the very instrument for which the entire mission was named, appeared to be a dud. That’s a bad day at work by anyone’s standards, and it happened over the summer when it was reported that the Mars Interior Exploration using Seismic Investigations, Geodesy and Heat Transport lander’s Heat Flow and Physical Properties Package (HP³), commonly known as “The Mole”, was not drilling itself into the Martian regolith as planned.

But now, after months of brainstorming and painstaking testing on Earth and on Mars, it looks as if the mole is working again. NASA has announced that, with a little help from the lander’s backhoe bucket, the HP³ penetrator has dug itself 2 cm into the soil. It’s a far cry from the 5-meter planned depth for its heat-transfer experiments, but it’s progress, and the clever hack that got the probe that far might just go on to salvage a huge chunk of the science planned for the $828 million program.

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Developing Guidelines For Sustainable Spaceflight

October 22, 2019 by 18 Comments

In the early days of spaceflight, when only the governments of the United States and the Soviet Union had the ability to put an object into orbit, even the most fanciful of futurists would have had a hard time believing that commercial entities would one day be launching sixty satellites at a time. What once seemed like an infinite expanse above our heads is now starting to look quite a bit smaller, and it’s only going to get more crowded as time goes on. SpaceX is gearing up to launch nearly 12,000 individual satellites for their Starlink network by the mid-2020s, and that’s just one of the “mega constellations” currently in the works.

Just some of the objects in orbit around the Earth

It might seem like overcrowding of Earth orbit is a concern for the distant future, but one needs only look at recent events to see the first hints of trouble. On September 2nd, the European Space Agency announced that one of its research spacecraft had to perform an evasive maneuver due to a higher than acceptable risk of colliding with one of the first-generation Starlink satellites. Just two weeks later, Bigelow Aerospace were informed by the United States Air Force that there was a 1 in 20 chance that a defunct Russian Cosmos 1300 satellite would strike their Genesis II space station prototype.

A collision between two satellites in orbit is almost certain to be catastrophic, ending with both spacecraft either completely destroyed or severely damaged. But in the worst case, the relative velocity between the vehicles can be so great that the impact generates thousands of individual fragments. The resulting cloud of shrapnel can circle the Earth for years or even decades, threatening to tear apart any spacecraft unlucky enough to pass by.

Fortunately avoiding these collisions shouldn’t be difficult, assuming everyone can get on the same page before it’s too late. The recently formed Space Safety Coalition (SSC) is made up of more than twenty aerospace companies that realize the importance of taking proactive steps to ensure humanity retains the unfettered access to outer space by establishing some common “Rules of the Road” for future spacecraft.

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