Shortly thereafter, SpaceX confirmed the existence of the test vehicle development program, and projected it would begin the Grasshopper flight test program in 2012.
Releases of public information in 2011 indicated that the subsonic tests would occur in McGregor, Texas in three phases, at maximum flight altitudes of 670 to 11,500 ft (200 to 3,510 m), for durations of 45 to 160 s (0.75 to 2.67 min). At the time, testing was expected to take up to three years and the initial FAA permit allows up to 70 suborbital launches per year.
A half-acre concrete launch facility was constructed to support the test flight program. In September 2012, SpaceX announced that they have requested FAA approval to increase the altitude of some of the initial test flights. Looking forward to the next year, CEO Musk said in November 2012: "Over the next few months, we'll gradually increase the altitude and speed. ... I do think there probably will be some craters along the way; we'll be very lucky if there are no craters. Vertical landing is an extremely important breakthrough — extreme, rapid reusability."
In May 2013, SpaceX announced that the higher-altitude, higher-velocity part of the Grasshopper flight test program would be done at Spaceport America near Las Cruces, New Mexico—and not at the Federal Government's adjacent White Sands Missile Range facility as previously planned—and signed a three-year lease for land and facilities at the recently operational spaceport. SpaceX indicated in May 2013 that they did not yet know how many jobs might move from Texas to New Mexico.
The F9R Dev1 vehicle in Texas was intended to take off and accelerate with three engines—as the test flight never needs the full thrust to take off a fully loaded Falcon 9 with an orbital payload—while completing the descent and landing with only one engine. The original Grasshopper had flown exclusively with only a single Merlin 1D engine in place, the center engine which is now used to complete the last phase of the deceleration and vertical landing on full-scale Falcon 9 rockets.
A third flight test vehicle—F9R Dev2—was initially planned to be flown only at the high-altitude test range at Spaceport America and at altitudes of up to 91,000 meters (300,000 ft). In September 2014, following the destruction of the F9R Dev1, SpaceX changed the plans, so the F9R Dev2 vehicle would fly first in McGregor for low-altitude testing. The initial FAA permit to fly the Falcon 9 Reusable Development Vehicle at McGregor in Texas was open until February 2015.
On 19 February 2015 SpaceX announced that the F9R Dev2 would be discontinued.
In May 2015, a press article stated that due to the technical success of many aspects of the booster rocket landing attempts on the sea and on the ASDS, SpaceX was planning on using the New Mexico site for testing the returned stages.
Flight tests at the Texas facility were limited to a maximum altitude of 2,500 ft (760 m) by the initial FAA regulatory permit.
From the announcement in 2011 until 2014, SpaceX has achieved each of the schedule milestones that they publicly announced. SpaceX said in February 2012 that they were planning several vertical-takeoff, vertical-landing (VTVL) test flights during 2012, and confirmed in June 2012 that they continued to plan to make the first test flight within the next couple of months.
SpaceX performed a short-duration ground test (static test) of F9R Dev1 on March 28, 2014, at their McGregor, Texas test site, and made their maiden test flight of the new vehicle, to an altitude of 250 meters (820 ft), on April 17, 2014. The F9R Dev1 flew for the fifth and last time on August 22, 2014. During this flight, anomalous sensor data from the vehicle during its ascent caused the rocket to deviate from nominal flight trajectory, prompting its flight termination system to end the mission by neutralizing the vehicle. No injuries or near-injuries were reported following the breakup of F9R Dev1 and an FAA representative was present during the test. Video from the accident was released by CBS and multiple images from the accident were posted on social media.
In 2013, SpaceX moved to using their mainstream Falcon 9 vehicles for VTVL testing, in addition to their existing tests with flying test vehicles. In March 2013, SpaceX announced that, beginning with the first flight of the stretch version of the Falcon 9 launch vehicle—the sixth flight overall of Falcon 9 (then anticipated for summer 2013), every first stage would be instrumented and equipped as a controlled descent test vehicle. SpaceX attempted numerous over-water landings, both over the sea, resulting in soft landings into the water, and onto specialized Autonomous Spaceport Drone Ships, barges modified to be landing platforms. None were completely successful.
SpaceX eventually succeeded in landing a production vertical-landing rocket on land in late 2015. The first attempt to land the first stage of the Falcon 9 on land, near its launch site, occurred on Falcon 9 Flight 20, on 21 December 2015. The landing was successful, and the first stage of the Falcon 9 Full Thrust vehicle was recovered. By May 27, 2016, SpaceX had successfully completed three first-stage landings on a drone ship at sea.
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F9R First Flight Test | 250m. SpaceX. 18 April 2014. Archived from the original on 5 February 2023. Retrieved 17 April 2023 – via YouTube. https://www.youtube.com/watch?v=0UjWqQPWmsY
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