#47 - Building a MASSIVE Mach 25 Space Gun in the Desert | Mike Grace, CEO Longshot

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#47 - Building a MASSIVE Mach 25 Space Gun in the Desert | Mike Grace, CEO Longshot
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Summary

  • Mike Grace, co-founder and CEO of Longshot, is building a kinetic launch system — a massive “space gun” in the desert — to put payloads into orbit at a fraction of rocket costs by keeping all launch energy on the ground instead of carrying it aloft.

The core concept: kinetic launch vs. rockets

  • A rocket carries all its energy (fuel, tanks, engines) and only ~1% of its mass reaches orbit as payload; the rest is infrastructure for lifting fuel.
  • With kinetic launch, the accelerator stays on the ground (built from concrete and mild steel pipe), and only the projectile goes to space, dramatically lowering marginal cost.
  • The idea dates to Jules Verne and Newton; Grace frames it as “stealing 1930s–1960s German engineering” — if you want to succeed in aerospace, find what a German worked on then and adapt it.

Historical lineage: German superguns and the V-3

  • WWI Paris Guns fired 1-ton projectiles 120+ km but eroded barrels in ~60 shots from combustion heat.
  • WWII V-3 (Hochdruckpumpe) used a distributed-injection “pipeline” on a hillside: multiple side chambers fired sequentially down the bore, halving peak pressure, temperature, and acceleration per doubling of injections.
  • This let the Germans build from ordinary sewer pipe (mild steel, ~1,000 psi peak pressure) instead of exotic gun barrels.
  • The V-3 was immobile and vulnerable to bombers; post-war, the US/USSR prioritized rockets (V-2 lineage) for nuclear deterrence where marginal cost and reliability mattered less.

Gerald Bull and Project HARP

  • Canadian ballistician Gerald Bull built HARP (High Altitude Research Project) in the 1960s: two 16-inch battleship guns welded end-to-end in Barbados, firing projectiles to 200+ km altitude (suborbital).
  • He aimed to add a small solid upper stage to put ~1 kg in orbit by 1964–65, but the Army/Air Force killed it — fixed infrastructure duplicating missile silos wasn’t strategically compelling when 1 kg payloads had no market (cubesats didn’t exist).
  • Bull later worked for South Africa (CIA-backed), went to prison, then built a supergun for Saddam Hussein; assassinated in Belgium in 1990. Grace’s takeaway: “Don’t build death stars for dictators.”

Why SpaceX isn’t pursuing kinetic launch

  • US + USSR spent ~$4 trillion on rockets since WWII; rockets exist primarily for suborbital nuclear delivery — orbital launch is a “happy accident.”
  • Elon Musk has tens of billions sunk into Starship; Grace argues first-principles from 150 years ago (marginal cost focus) point to guns, not rockets, but Musk won’t pivot.
  • Grace wants Starship to succeed (he’ll ride a rocket; humans can’t survive gun G-loads), but believes rockets hit a physics floor: they’re flying bombs requiring extreme safety overhead, limiting how low marginal cost can go.

Cost per kg to orbit: historical and projected

  • Shuttle era: ~$72,000/kg (Grace calls it a Nixon-era boondoggle).
  • Falcon 9: ~$3,000–$5,000/kg today; SpaceX aspirational $1,100/kg go-to-market, but Grace suspects floor ~$250/kg at cost.
  • Starship aspiration: $100/kg; Grace skeptical — thinks $250/kg is more realistic floor even at massive scale.

Longshot’s cost target with a space gun

  • MVP (“Baby Bear”): ~$150/kg go-to-market, ~500 kg payload (2–3 small commsats), 10–20 km tube, 150–250 g acceleration.
  • “Mama Bear”: 20-ton payload, direct Falcon 9 competitor.
  • “Papa Bear”: 100-ton payload (full Starship as bullet), 7–8 m bore, ~70 km long, multi-billion-dollar concrete structure.
  • Long-term marginal cost dominated by electricity; could drop below $10/kg as solar/SMR nuclear cheapens power.

Current prototype: reaching Mach 4.2

  • 70 cm (29 in) bore, mild steel pipe, ~$40k bill of materials; per-shot cost ~$5k (not optimized for turnover).
  • Uses helium (safe in Oakland); hydrogen would reach Mach 6 but too hazardous for urban test site.
  • Key technical risk retired: precise, repeatable, microsecond-level timing of high-pressure side injection valves at hypersonic speeds.
  • Achieved Mach 4.2 with intact projectiles; bits at Mach 4.5; Mach 6 possible with H₂.

Scaling from Mach 5 to Mach 15: the DoD wedge

  • Gap between garage prototype and orbital gun too wide for VC appetite; DoD hypersonic test market bridges it.
  • Current DoD hypersonic flight tests cost ~$15M (sounding rockets); Longshot offers same for ~$150k (2 orders of magnitude cheaper).
  • Applications: hypersonic vehicle/test article free-flight (scramjets, heat shields, sensors), Missile Defense Agency targets.
  • A 1-km, 1-m bore desert system doing Mach 15 creates a “meteor” on exit; Grace sees the jump from Mach 15 to Mach 25 as “a little crack of light” once the test infrastructure exists.

Heat shielding and the ballistic coefficient imperative

  • Aerodynamic heating scales with velocity³; drag and ablation scale with surface area (²), but mass and thermal capacity scale with volume (³).
  • Small projectiles burn up or slow down; must go big and dense. Threshold: ~2 m diameter, multi-ton vehicle.
  • 2-ton vehicle sacrifices ~50% mass to ablation (vs. 3% for Apollo, which decelerated high in atmosphere).
  • 20-ton vehicle: ~2 tons ablation, far more efficient. Vehicle must be cheap — “wood chips and phenolic resin,” solved by Soviet-style brutal scale.

Finding a 20 km stretch of land: real estate > engineering

  • Ideal site: where you could detonate a nuke and no one would notice — remote, sparse population, cooperative government.
  • US lower-48 airspace too dense; shutting down corridors for daily launches impractical.
  • Australia (Outback, Northern Territory): twice Texas land area, <1% population, no indigenous launch access — strategic win for them.
  • Alaska has land but cold; Grace prefers Australia.
  • Community buy-in is critical: Tonopah, NV (pop. ~1,500) welcomed Longshot for hypersonic test site; town council lobbied county/state. “You can’t cram a project down a town’s throat; they have to want you.”

Rapid reusability via low pressure/temperature

  • Distributed injection + long tube = lower peak pressure (~1,000 psi, ⅓ scuba tank) and temperature (a few hundred °C vs. mantle-of-sun in artillery).
  • Energy invested over length/time; no violent single event. Barrel is essentially a concrete vacuum hallway (atmosphere pumped out before firing).
  • No fundamental physics barrier; 2D gas dynamics are well-understood. Risk concentrates in atmospheric transit (Mach 15–25), not the accelerator.

Early iterations: garage PVC potato guns

  • Started in Grace’s garage with Home Depot PVC, multi-injection “potato gun,” Mach 1.8 at 40 ft.
  • Grace (economist/molecular biologist) and COO Brendan (9 ft tall) — neither are engineers — built it with no salary for 1.5 years.
  • PVC fails catastrophically, softens in sun; vessels exploded behind steel plates. “Scary as hell.”
  • Mach 1.8 on PVC for ~$13k total spend; SpinLaunch spent ~$140M for Mach 1.6.

Unique test facility: abandoned Navy gun range

  • Alameda Point (former Naval Air Station): 300-ft × 20-ft × 20-ft hallway, used for Phalanx CIWS testing, bullet spray marks on walls.
  • Closed since 1990s; city permits raves occasionally. Perfect for Longshot — modern enough to avoid asbestos, insane acoustics.
  • Grace regrets not finding it 4 years earlier.

Building the desert test site: political economy, not just tech

  • Critical path is community → county → state → federal buy-in, not engineering.
  • SpinLaunch’s Hawaii town hall disaster: locals feared property values, cat cancer, sonic booms.
  • Technologists underestimate this; extractive industries (mining, oil) know the game.
  • Longshot is an infrastructure project (Panama Canal for space), with infrastructure problems and benefits.

Competitors in kinetic launch

  • SpinLaunch: centrifuge approach, ~$140M spent, Mach ~1.6, now pivoting to DoD non-orbital work.
  • RIA (LA): electromagnetic/railgun approach; Grace jokes “Insane Clown Posse fundamentally recapitulates my thesis on magnets.”
  • Green Launch: John Hunter (light-gas gun pioneer); Grace credits Hunter’s 2010 talk for sparking his interest. Green Launch winding down.

Hiring advantage: cool problems attract talent

  • Aerospace engineers take 50% pay cuts vs. chemical engineering to work on rockets; they care about mission.
  • SpaceX exploits this (grueling culture); Longshot offers similarly cool, hard problems without the abuse.
  • Grace: “Give these people something cool to work on and they’ll break themselves for you.”

Vision: open the solar system, drive launch price to zero

  • Earth is homogenizing (languages, cultures, travel, AI translation); diversity requires separation + different conditions.
  • No elbow room left on Earth; need new frontiers for weirdos (Mormons on Enceladus, Trotskyites on asteroids) to run societal experiments.
  • Target: launch cost → $0 (like airmail to Europe). Business model: own the railroad, monetize downstream (in-space solar, asteroid mining, ads on the Moon).
  • Cheap bulk launch enables orbital refueling (15 Starships → 1 Mars ship becomes trivial), heavy industry off-Earth, Earth as a garden.

Near-death experiences: three near-bankruptcies

  • First: $4k in bank, wife paying rent, sleeping at build site; saved by Air Force Direct-to-Phase-II SBIR.
  • Founder psychology: must spend as if money will arrive, shortening runway; if it doesn’t, you cut team pay or fold.
  • Latest raise: Grace, COO, biz team went to $0 salary; engineering took 25% cut (CTO 50%); only paternity-leave staff spared.
  • “You put faith in me and I failed you” — recurring founder burden on hard tech; not the hardest thing Grace has done, but hard.
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