Starbase, a sprawling launch-and-manufacturing site that recently incorporated as its own Texas city, logged injury rates that were almost 6x higher than the average for comparable space vehicle-manufacturing outfits and nearly 3x higher than aerospace manufacturing as a whole in 2024, according to Occupational Safety and Health Administration (OSHA) data released in May. That outsized injury rate has persisted since 2019, when SpaceX began sharing Starbase injury data with the federal regulator. Starbase is home to SpaceX's most ambitious program: a fully reusable, ultra-heavy-lift rocket called Starship. The company has been moving at a breakneck pace to bring Starship online to launch Starlink internet satellites and other payloads. Since Starship's first orbital test in April 2023, SpaceX has attempted eight additional integrated flights. During three of those tests, the company made history by catching the massive Super Heavy booster with 'chopstick' arms attached to the launch...
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