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SpaceX Falcon 9 “Block 5” next-gen reusable rocket spied in Texas test site

SpaceX Block 5 Falcon9 at McGregor, Texas [Credit: Chris G - NSF via Twitter]

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SpaceX’s next and final generation of Falcon rockets is nearly ready to complete its biggest milestone yet, second only to operational launch. Known as Falcon 9 Block 5, the upgraded booster arrived at SpaceX’s McGregor, TX test facilities and went vertical on the static fire test stand.

Now vertical, that first integrated static fire is likely to occur within a handful of days at most. Once complete, assuming the data it produces do not betray any bugs or serious problems, the booster will be brought horizontal and transported to one of SpaceX’s three launch facilities for its first operational mission.

Why Block 5?

With nary a hint of hyperbole, it’s safe to say that Falcon 9 Block 5 will be the most significant piece of hardware ever developed and fielded by SpaceX. The reason lies in many of the changes and upgrades present in this newest iteration of the rocket. While Falcon 9 B5 and its similarly upgraded Merlin 1D engines include design changes intended to satisfy NASA requirements before SpaceX can be certified to launch humans, the brunt of the upgrades are laser-focused on ease and speed of reusability.

Photo courtesy of Chris G at nasaspaceflight.com via Twitter. Reprinted with permission.

The goal with those upgrades, as publicly stated by numerous SpaceX executives, is to enable as many as 10 flights with a bare minimum of refurbishment and 100 or more launches with intermittent maintenance. To achieve those titanic aspirations, SpaceX has gathered a flood of data and experience earned through the recovery of nearly 20 Falcon 9 and Heavy boosters, as well as the successful reflight and second recovery of several of those same boosters. With that data in hand, the company’s launch vehicle engineers optimized and upgraded the rocket’s design to combat the worst of the extreme forces each booster is subjected to while returning to land (or sea).

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As evidenced by photos taken by Gary Blair, one of NASASpaceflight.com‘s most renowned L2 forum contributors, many of the visible differences between Block 5 and previous versions of Falcon 9 are a result of drastically improved and expanded heat shielding of its most sensitive and crucial components. While Falcon 9 B5’s black sections by all appearances look like naked carbon fiber composite, they are likely to be coated with an incredibly heat-resistant material known a Pyron. Portions of the booster that suffer from incidental scorching and extreme heating (aside from the octaweb) appear to have been treated with this material, including a pathway down the side of the rocket known as a raceway. The raceway is a protective enclosure for a variety of cabling and piping, essentially the rocket’s nervous system as well as the home of several the cold gas thrusters it uses to orient itself outside of Earth’s atmosphere.

In the past, SpaceX has used high-quality cork as a quasi-ablative thermal protection system for those same components, including the payload fairing. A major downside of cork, however, is that it is very ablative and tends to come off rather haphazardly in large chunks, all of which must either be spot-fixed or replaced entirely before a booster reflight. By replacing that cork with Pyron or a similar internally-developed material, those sensitive Falcon components may be almost totally insulated from and resistant to temperatures as high as 2300 °F (1200 °C)

Titanium grid fins are another central feature of Block 5, acting as a near-indefinitely reusable replacement for the aluminum grid fins SpaceX has traditionally used. Put through a huge amount of heating during reentry; aluminum grid fins have famously appeared to partially melt during some of the hottest booster recovery attempts. Titanium, a metal with a much higher melting point, will have no such problems, does not need ablative white paint, and certainly appear all but untouched by reentry in the cases of both their June 2017 debut and second flight on Falcon Heavy’s side boosters.

Finally and perhaps most importantly, is the octaweb – the assembly at the base of Falcon 9 responsible for safely transmitting nearly two million pounds of thrust from its nine Merlin 1Ds to the rest of the rocket’s structure, while also taking the brunt of the heat of reentry. Before Block 5, the octaweb was protected from that heating with an ablative thermal protection system, likely around 80% cork and 20% PICA-X, the same material used on Cargo Dragon’s heat shield. Based on comments made privately by individuals familiar with SpaceX, that ablative shielding is to be replaced by a highly heat-resistant metal alloy known as inconel. By ridding Block 5 of ablative heat shielding, SpaceX will no longer have to carefully examine and replace those materials after each launch, removing one of the biggest refurbishment time-sinks.

Titanium grid fins complete the highly reusable changes to Block 5 of Falcon 9. (NASA)

Combined, these various upgrades are intended to enable Falcon 9’s first stage to be reused almost effortlessly compared to previous iterations. With this vehicle, including the reusable fairing debuted on the launch of PAZ, SpaceX may well be able to achieve Elon Musk’s famous goal of lowering the cost of launch by nearly an order of magnitude. While SpaceX will likely use that cost reduction to first recoup its considerable investments in reusability and Falcon Heavy, major price drops may reach customers soon after. This Falcon 9, in particular, is unlikely to launch for another month or so, but when it does, it is perhaps the biggest step SpaceX has yet taken on the path to routine, rapid, and affordable access to orbit.

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Eric Ralph is Teslarati's senior spaceflight reporter and has been covering the industry in some capacity for almost half a decade, largely spurred in 2016 by a trip to Mexico to watch Elon Musk reveal SpaceX's plans for Mars in person. Aside from spreading interest and excitement about spaceflight far and wide, his primary goal is to cover humanity's ongoing efforts to expand beyond Earth to the Moon, Mars, and elsewhere.

Investor's Corner

Tesla Q3 2025 earnings: What analysts expect

The automaker delivered a record 497,099 vehicles and logged its highest-ever energy storage sales in Q3 2025. 

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Credit: Tesla China

Tesla’s (NASDAQ:TSLA) Q3 2025 earnings, which would be released after markets close today, could prove to be a test of confidence for the company’s shareholders. 

The automaker delivered a record 497,099 vehicles and logged its highest-ever energy storage sales, but analysts noted that these gains might have come at a cost. 

Record vehicle deliveries

Tesla’s profit per share is expected to fall about 25% year over year to around $0.53–$0.55, even as revenue rises from 4% to 6%, as noted in a report from Market Pulse. Analysts noted that Tesla’s record quarter was partly fueled by buyers rushing to complete purchases before the U.S. federal EV tax credit expired in September, a surge that could dampen Q4 demand. The company also dipped into its inventory to reach the record delivery number.

Analysts expect automotive gross margin (excluding regulatory credits) to land between a conservative 16.5% and 17%. This suggests that a good portion of Tesla’s Q3 delivery growth came from aggressive price cuts. If margins fall below 16.5%, it could hint at more cost pressures that the company would have to handle in the coming months.

Tesla’s Energy segment, meanwhile, is expected to act as a stabilizer. The business deployed 12.5 GWh of storage in Q3, driven by strong demand from AI data centers. Analysts expect this high-margin division to partially cushion the hit from the automaker’s thinner car profits.

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AI, FSD, and Musk’s role

Tesla’s lofty valuation, trading about 17% above the average analyst consensus of $365, would likely depend heavily on investor belief in its AI and robotics initiatives. Industry watchers have stated that management must deliver credible updates on Full Self-Driving and the Robotaxi program to help justify the company’s current valuation.

Elon Musk’s proposed 2025 CEO Performance Award, which proxy advisors have urged shareholders to reject, would likely be discussed in the Q3 2025 earnings call has well. Musk has hinted that a failed vote could jeopardize Tesla’s AI strategy, making the company’s upcoming results quite crucial for market confidence.

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Investor's Corner

Tesla Board Chair defends Elon Musk’s pay plan, slams proxy advisors

The letter comes ahead of Tesla’s 2025 Annual Meeting, where shareholders will vote on several key proposals.

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robyn-m-denholm-tesla
CeBIT Australia, CC BY 2.0 , via Wikimedia Commons

Tesla Chair Robyn Denholm has issued a strongly worded letter urging investors to reject the latest recommendations from proxy advisory firms ISS and Glass Lewis, saying their “one-size-fits-all” approach fails to recognize Tesla’s unique business model and track record. 

The letter comes ahead of Tesla’s 2025 Annual Meeting, where shareholders will vote on several key proposals including Elon Musk’s 2025 CEO Performance Award and director reelections.

Tesla slams proxy advisors’ models

Denholm criticized both firms for consistently opposing Tesla’s growth-oriented plans, noting that the company’s market capitalization has increased twentyfold since shareholders approved Musk’s 2018 performance package, which both advisors had opposed at the time. 

“Our shareholders have ignored their recommendations, and it’s a good thing they did,” she wrote. “Otherwise, you may have missed out on our market capitalization soaring 20x while the proxy advisors time and time again recommended “against” Tesla proposals designed to promote the sort of extraordinary growth we have enjoyed.”

The letter argued that Glass Lewis and ISS use robotic policies that don’t account for Tesla’s innovation-driven structure. Tesla’s leadership maintained that the 2025 CEO Performance Award will only reward Musk if he achieves extraordinary market capitalization and operational goals. The plan, Denholm stated, aligns Musk’s incentives with long-term shareholder interests.

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Tesla defends board leadership

Denholm also defended directors Ira Ehrenpreis and Kathleen Wilson-Thompson, calling them pivotal to Tesla’s governance and innovation strategy. She said both have driven Tesla’s growth and helped design compensation systems vital to competing in the AI and robotics talent race.

She warned that following ISS and Glass Lewis could turn Tesla into “just another car company,” and urged shareholders to “vote yes to robots, and reject robotic voting.” The letter also highlighted that neither ISS nor Glass Lewis owns Tesla stock, emphasizing that only shareholders “who have made an actual financial investment” should decide the company’s direction.

“If you prefer that Tesla turn into just another car company mired in the ways of the past, then you should follow ISS and Glass Lewis. If you believe that Tesla, under the visionary leadership of Elon and the oversight of a Board that includes business leaders with integrity like Ira, Kathleen and Joe, then you should vote with Tesla,” Denholm wrote.

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Tesla Model S and Model X make a comeback in Europe

The updates inside and under the surface of the new Model S and Model X are meaningful.

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Credit: Tesla Europe & Middle East

Tesla’s luxury flagships are making a comeback in Europe. After disappearing from Tesla’s online configurator in July, the Model S and Model X are once again available to order across the region. 

Deliveries are set to begin in November, with the Model S priced from €109,990 and the Model X starting at €114,990. The update brings improved comfort, reduced cabin noise, and efficiency improvements to the two veteran EVs.

A subtle refresh

Tesla’s design team made only light exterior changes, but the updates inside and under the surface of the new Model S and Model X are meaningful. The refreshed Model S and Model X now feature upgraded insulation, enhanced active noise cancellation, and retuned air suspension to make the ride smoother and quieter. 

New 19- or 21-inch wheels and ambient interior lighting add a subtle modern touch to the two flagships, while the Model X’s third-row seating has been improved with more space for occupants, Tesla Europe and Middle East noted in a post on X.

Both vehicles gained adaptive headlights, blind-spot warning lights, and a standard front camera. Efficiency has also improved thanks to new aerodynamic rims and low-rolling-resistance tires. The Model S now boasts a WLTP range of 744 kilometers, while the heavier Model X can travel up to 600 kilometers on a single charge.

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Tesla’s performance flagship

The Model S Plaid, Tesla’s performance flagship, benefits from deeper upgrades in this cycle. The vehicle now features a redesigned front fascia and a new front splitter. Its rear aprons have also been updated, and it has been given a carbon rear spoiler and diffuser to enhance high-speed stability. 

Underneath, the drive rotors receive carbon sleeves for better performance under extreme loads. The Plaid sprints from zero to 100 kph in just 2.1 seconds and can reach 322 kph with optional ceramic brakes, while maintaining an impressive 611-kilometer range. Considering its performance figures, the Model S Plaid has once again become the market’s best bang-for-the-buck flagship performance car. 

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