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LaunchPad: Falcon Heavy ready to go for commercial launch debut

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This is a free preview of LaunchPad, one of Teslarati’s member-only launch briefing newsletters. Before each SpaceX launch, I’ll give you an inside look of what to expect and share amazing photos and on-the-ground details after the launch. Become a member today receive all of Teslarati’s newsletters.

SpaceX launch technicians and engineers have officially completed the integration and static fire testing of the second Falcon Heavy rocket ever, nearing the end of preflight preparations for the vehicle’s critical commercial launch debut. 

Carrying the commercial communications satellite Arabsat 6A, the rocket will be tasked with placing the massive spacecraft into a high-energy geostationary orbit. After a combination of hurdles and conflicting priorities conspired to delay Arabsat 6A’s launch from mid-2018 to February, March, and eventually, April of 2019, both the spacecraft and rocket are nearly ready to go. If all goes as planned, SpaceX will also complete the first successful launch and near-simultaneous landings of three independent rocket boosters, preparing two of the three boosters for reuse on a launch that could happen as early as June 2019.

When: 6:35 pm EDT, 22:35 UTC (click for your time), April 10th
What: Arabsat 6A, communications satellite, ~6000 kg (13,200 lb)
Where: Pad 39A, Kennedy Space Center, Florida
Boosters: B1052.1, B1053.1, B1055.1
Recovery: Yes; drone ship Of Course I Still Love You (OCISLY) & LZ-1/2
Weather: 80% GO, 4/10

SpaceX technicians work to integrate the assembled Falcon Heavy first and second stages to the transporter/erector (T/E) ahead of a static fire test on April 5th. (SpaceX)

Falcon 9 Block 5, meet Falcon Heavy

  • With this Falcon Heavy, SpaceX has effectively built – once again – a center stage that is nearly its own rocket, much like the tortured development of the first vehicle’s center stage can be blamed for a lot of its years of delays. 
    • Based on Falcon 9 V1.2’s Block 3 iteration, Falcon Heavy Flight 1’s center core was effectively outdated a year before it launched, and Falcon 9 Block 5 debuted just three months after its first and last launch.
  • Combined with the center core’s untimely demise when it crashed into the Atlantic after running out of engine starter, the now 14 months separating Flight 1 and Flight 2 of Falcon Heavy can be explained by the rocket’s delayed path to the launch site.
    • By the time the first Falcon Heavy’s main components were all present in at the launch site, SpaceX was already building Block 5 rockets and was as few as three months away from completely transitioning its Hawthorne, CA factory to Block 5. 
    • Due to the extensive changes in production incorporated into Block 5, this was effectively a no-turning-back deal where the cost of transitioning back was simply a non-starter.
    • By the time Falcon Heavy had launched, and its center core had smashed itself to pieces on the Atlantic Ocean surface, it was far too late to begin producing a replacement copy. One step further, the process of ramping up Block 5 production had been slowed significantly by the drastic changes made across the board, taking SpaceX to the edge of production-related launch delays over the course of 2018.
  • Put simply, building two side boosters and a relatively boutique Falcon Heavy center core – all three of which would be inextricably tied together for the foreseeable future – was not a practical option when three separate Falcon 9 Block 5 boosters could instead support 6-12+ launches over a period of six or so months.

(Hopefully) the first of many

  • In the nominal event that SpaceX’s second Falcon Heavy launch is an unqualified success, it’s entirely possible that the doors to new markets could be opened as the world and its many spacefaring customers begin to contemplate the existence of an affordable super-heavy-lift launch vehicle – the first of its kind.
    • On the outside, Falcon Heavy can begin to look like a bit of a boondoggle from a business perspective. It will have probably cost no less than $750M-$1B to develop, including the Block 5 modifications needed, and likely brought in less than $100M in gross revenue. It’s a black hole that SpaceX currently dumps huge volumes of cash into, in other words.
    • However, this sort of observation is far too pessimistic and gives SpaceX far too little credit after some additional careful analysis. As of today, SpaceX has six public launch contracts for FH, two of which are from the USAF/NRO and likely valued around $130M-$150M.
    • Purely commercial contracts for Falcon Heavy will probably be closer to $90M-100M, more than competitive with rockets like Atlas 5, Delta IV Heavy, Ariane 5, and other future vehicles like ULA’s Vulcan.
  • Within ~12 months, the USAF will likely have awarded 10-16 additional launch contracts to some combo of Falcon 9 and Falcon Heavy as part of the latest EELV (now NSSL) acquisition phase. Assuming SpaceX is one of the two providers chosen, Falcon Heavy could receive numerous additional contracts for heavy military satellites.
    • Additionally, NASA is now seriously considering Falcon Heavy for the launch of flagship missions like Europa Clipper and (maybe, maybe not) even Orion missions to the Moon.
    • Falcon Heavy could also be the only vehicle in the world with the performance needed for a number of other missions that could arise from the Lunar Gateway, including launching actual segments of the space station and launching deep space cargo missions resupply said Gateway.
  • Only ULA’s Delta IV Heavy can marginally compete with Falcon Heavy’s performance, but it typically costs no less than $300M per launch, a 2-3X surcharge over SpaceX’s offering. Due to the utter and complete lack of competition from both a price and performance perspective, SpaceX could essentially have the heavy life market cornered for something like 48-60+ months.
    • Offering a unique product with potentially high demand and no real alternative, SpaceX would not be out of place to raise its profit margins significantly, helping to rapidly pay back the capital investment it put into Falcon Heavy’s extended development.
    • Regardless, the future of Falcon Heavy has every right to be even more thrilling and diverse than the already impressive Falcon 9.
The above photos show HellasSat-4/SaudiGeoSat-1, a nearly identical sister satellite to Arabsat 6A, both based on Lockheed Martin’s modernized A2100 satellite bus. At the bottom, a photo from the 45th Space Wing shows off what appears to be a conspicuously flight-proven nose cone, potentially taken from one of Falcon Heavy Flight 1’s two side boosters. (Lockheed Martin/45th Space Wing)

You can watch Falcon Heavy’s commercial launch debut live here on April 10th at 6:35 pm EDT (22:35 UTC). We’ll see you after the launch at LandingZone with exclusive photos and on-the-ground details of Falcon Heavy’s center core recovery.

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.

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Tesla eyes supply partners for Optimus mass production

Tesla certified three Chinese suppliers for Optimus mass production, signaling its robot timeline is accelerating.

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Concept rendering of Tesla Optimus in mass production

Tesla’s robotics team traveled to Ningbo, in China’s Zhejiang province, on September 16 and spent the following day auditing component suppliers for Optimus, according to a Bloomberg report cited by RobotAIGeek. The visit moved three manufacturers from provisional status to certified mass production partners: Tuopu Group, which handles actuators and chassis components, Ningbo Joyson Electronic, a sensor supplier, and Zhejiang Sanhua Intelligent Controls, which builds thermal management systems. All three already supply parts to Tesla’s electric vehicles, and the audit reportedly came with fresh orders that supply chain reports put at an initial batch of roughly 5,000 units.

Tuopu, Joyson, and Sanhua built their manufacturing base serving the automotive industry, where tolerances and volume requirements are already close to what a mass produced humanoid robot demands. Sanhua in particular has history here. Teslarati reported last October that the company had received a roughly $685 million order for linear actuators tied to Optimus, a volume industry watchers estimated could cover around 180,000 robots once production ramped.

Supply chain reports tied to this week’s audit put Tesla’s near term production goal at about 1,000 Optimus units a week by late September, rising to 2,000 to 2,500 units a week by the end of the year. That pace would put real weight behind the timeline Tesla has been building toward since May, when it wound down Model S and Model X production at Fremont to convert that floor space into a dedicated Optimus line targeting one million units annually. JPMorgan analysts who toured the factory in August confirmed the conversion took roughly four months, a pace Musk has called unprecedented for a facility that size.

New drone video shows Tesla’s Optimus Factory reaching a turning point

Fremont is only the first phase. A second, larger Optimus plant is rising at Gigafactory Texas, where drone footage shared by Joe Tegtmeyer last week showed the structural steel nearing completion on the north end of the building. Tesla has said that facility is meant to eventually support production of up to 10 million units a year, though volume output there is not expected before 2027.

Commercial sales of Optimus are still targeted for the second half of 2027, but production is expected to start well before then. JPMorgan analyst Rajat Gupta has said Tesla’s “Optimus Academy” program, which uses early units to collect real world training data inside Tesla’s own facilities, is expected to be running later this year. Bloomberg Intelligence analyst Ian Ma described the Ningbo audits as “a positive commercialization signal for China’s humanoid supply chain,” noting that sentiment could improve further if the visit leads to confirmed supplier nominations and larger orders. The Solactive China Humanoid Robotics Index rose about 1.4% on the news, though it remains down roughly 30% for the year.

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Elon Musk’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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