In the spring of 2014, I visited the Michoud Assembly Facility, based in Southern Louisiana. Already, technicians were building barrels for the Space Launch System rocket's core stage. And NASA was investing tens of millions of dollars to modernize Michoud to produce the rocket. At the time, an aerospace analyst for the Rand Corporation, Peter Wilson, explained that, "They’re throwing the money into this program, into places like Michoud, to make it very expensive to change course."
NASA has not changed course. And after at least 5.5 years, during which time NASA has spent more than $10 billion on the SLS rocket, they are finally almost done assembling that first core stage, consisting of two large fuel tanks, four main engines, and all of a rocket's associated plumbing.
One answer to the question of why this has taken so long, and required so much money, is that there has been a lack of urgency. Large complex development programs—like, say, super heavy lift rockets—work best with low levels of funding during the design phase, a spike during development, and then diminished funding during flight production. Instead, after Congress created the SLS rocket program with a baseline of about $2 billion a year, it kept funding at, more or less, flat levels plus inflation. This is a great strategy for creating and sustaining jobs, but it's a poor way to go about rocket development.
SpaceX's Starship prototype, fabricated in a field in South Texas in five months, offers a counter example. It's what a sense of urgency can accomplish.
The SLS rocket core stage, consisting of four space shuttle main engines, measures 64.6 meters tall, with a diameter of 8.4 meters. The Starship Mk1 vehicle is 50.0 meters tall, with a diameter of 9.1 meters. So they are roughly the same size. Neither is the complete rocket. On the launch pad, the SLS will have two very large side-mounted solid-rocket boosters, derived from the space shuttle. And Starship is actually the upper stage of SpaceX's next-generation rocket, Super Heavy.
By itself, the SLS core stage cannot get to orbit. In fact, according to physicist Scott Manley, without its side-mounted boosters a fully fueled SLS core stage cannot even lift off the launch pad. The SpaceX Starship prototype, with three Raptor engines instead of a full complement of six, also cannot get to orbit. But it should be able to reach at least 25 to 30km, said Manley, who has a popular rocket science YouTube channel.
The SLS rocket remains a couple of years from its maiden flight. Starship, however, will likely make a 20km flight in November, Musk said.
Perhaps the biggest difference between the two new rockets is the velocity of their development. The SLS core stage, which uses heritage technology from the space shuttle, including its main engines, has taken at least 5.5 years to build, and billions of dollars.
Starship Mk 1 didn't even exist until this spring, and it may leap off the pad before year's end. This appears to underscore the value of urgency and clarity of purpose. At SpaceX the urging comes from the top. As Musk said of schedules on Saturday night, "tight is right, long is wrong." And Starship has a clear exploration purpose as well, allowing humans to settle other worlds, and fuel optimism in humanity's future.