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v 0.9: 227 kg (500 lb)
v 1.0: 260 kg (570 lb)
v 1.5: ~306 kg (675 lb)[1]
v 2 mini: 800 kg (1,800 lb)
v 2.0: ~1,250 kg (2,760 lb)[2]
Bill Gerstenmaier, SpaceX’s vice president of build and flight reliability, said in May that engineers were in the process of certifying Falcon 9 boosters for up to 20 flights for Starlink missions. Launches with customer satellites may be limited to rockets with lower flight counts. NASA has only certified reused Falcon 9 boosters with five or fewer flights for the agency’s astronaut missions going to the International Space Station.
“That gives us a lot of capability to continue to reuse boosters and continue to keep flying,” Gerstenmaier said. “I think we are able to meet our manifest, plus some, with the boosters that we’ve got in work.”
SpaceX’s latest iteration of the Falcon 9 rocket design—called the Block 5—flew for the first time in 2018. At that time, SpaceX had the goal of launching each Falcon 9 Block 5 booster 10 times. With boosters still coming back in good shape after each flight, SpaceX extended the life to 15 launches and landings, according to a report last year by the trade magazine Aviation Week & Space Technology.
The magazine reported that SpaceX put booster components through vibration testing to four times the fatigue life of what they would experience over 15 flights, giving engineers confidence that the rockets will continue to fly successfully.
The company has around 16 flight-proven Falcon boosters in its fleet, with several more new-build rockets slated to fly by the end of the year. Each mission requires a brand new upper stage. Reusing the first stage and payload fairing not only cuts the company’s internal launch cost—a figure that is believed to be less than $30 million per Falcon 9 flight—it unlocks a higher flight rate without straining the factory.