SpaceX employees are more likely to be injured while working at Starbase than any of its other manufacturing facilities, according to company worker safety records reviewed by TechCrunch.
Starbase, a sprawling launch-and-manufacturing site that recently incorporated as its own Texas city, logged injury rates almost six times higher than the average for comparable space vehicle manufacturing outfits and nearly three times 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 tower.
The data suggests that SpaceX’s rapid progress comes at a cost. And while injury rates alone don’t provide a complete picture of the safety culture at Starbase, they do offer a rare glimpse into the working conditions of the world’s leading space company.
Breaking down Starbase numbers
Starbase City, an unincorporated town in Texas. Image Credits:SpaceX
OSHA uses a standardized safety metric called Total Recordable Incident Rate (TRIR) to measure a company’s safety record and compare it to industry peers, like Blue Origin and United Launch Alliance. The publicly available data has limitations. It doesn’t distinguish between minor injuries like stitches versus serious incidents such as amputations.
TechCrunch calculated the TRIR based on that data, which includes the total number of incidents and total number of hours worked by SpaceX employees at each site.
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