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Relativity Space’s first 3D-printed rocket booster passes early tests

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Relativity Space CEO Tim Ellis says that the startup’s first 3D-printed ‘Terran-1’ rocket booster has already completed a few significant tests after arriving at its Florida launch pad last month.

Terran-1 is an expendable two-stage launch vehicle that, when assembled for the first time, will measure around 33 meters (110 ft) tall, 2.3 meters (7.5 ft) wide, and weigh 9.3 tons (~20,500 lb) empty. Fueled by liquid oxygen and methane (methalox) and powered by nine small Aeon engines, the first Terran booster will produce around 90 tons (~200,000 lbf) of thrust at liftoff. Altogether, the rocket is designed to initially launch up to 1.25 tons (~2750 lb) to low Earth orbit, with plans to expand to 1.5 tons (~3300 lb) in the future. SpaceX’s Falcon 9, for context, measures 3.7 meters (12 ft) wide, 70 meters (~230 ft) tall, likely weighs around 30 tons (~65,000 lb) dry, and can launch 22.8 tons (~50,250 lb) to LEO in an expendable configuration. A single one of its nine Merlin 1D booster engines produces about as much thrust as the entire first stage of Terran-1.

While tiny in comparison, Terran-1’s booster is still a relatively large and powerful rocket, and testing it poses significant challenges. Instead of building a custom test stand elsewhere, Relativity has chosen to conduct almost all first-stage qualification testing at its Cape Canaveral Space Force Station (CCSFS) LC-16 pad. 

That plan increases the risk of the rocket damaging Relativity’s only available launch pad, significantly delaying launch preparations, but it also has the potential to save time by doubling as a launch pad shakedown. Aside from basic concrete features and foundations, LC-16 was essentially a blank slate when Relativity arrived, so qualifying the pad – virtually all of which is new and recently installed – is no small feat on its own.

LC-16, 2022. (Relativity Space)

Relativity’s first Terran-1 flight hardware has performed shockingly well. The smaller single-engine upper stage sailed through a full program of proof tests – including a full-duration static fire – shortly before shipping to LC-16. Terran-1’s first booster, meanwhile, left Relativity’s California factory and arrived at LC-16 to begin its own qualification testing in early June.

A frosty, venting Terran-1 booster is pictured during one of its first cryogenic tests. (Tim Ellis)

On June 28th, CEO Tim Ellis revealed that the booster had already completed “pneumatic proof testing” and made it through its “first propellant loading” test less than a month after arriving at LC-16. That would be fast for the first prototype of any new orbital-class rocket, but Relativity’s Terran-1 has an extremely unique feature that makes that speed even more impressive: by mass, the vast majority (85%) of the rocket was manufactured with 3D printing. In effect, most of Terran’s airframe and tanks are just giant, continuous welds that were precisely manipulated into cylinders, domes, and more. While the rough surface finish leaves something to be desired and likely reduces the overall efficiency of the rocket’s airframe, Relativity says that the composition of the metal in its printed structures is almost identical to a more traditionally-manufactured component.

Relativity’s ultimate hope is that the technical groundwork it is laying will allow it to manufacture complex and high-performance rockets with minimal human intervention, drastically lowering production costs. One day, the descendants of those semi-autonomous factories might even be used to construct rockets and other complex machines and infrastructure on Mars or other extraterrestrial destinations.

First, though, the company needs to start successfully launching Terran-1 rockets and fully prove the concept. Up next, Relativity will likely perform a full wet dress rehearsal, a launch simulation in which the rocket is loaded with propellant and pressurized for flight. Once that step is complete, Relativity will attempt one or several static fire tests, culminating in a full-duration multi-minute static fire or “mission duty cycle.”

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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.

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Elon Musk roasts India’s billionaire Mukesh Ambani as Starlink fight heats up

Elon Musk sarcastically calls Mukesh Ambani ‘Prime Minister’ as the Starlink India standoff escalates again.

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Elon Musk escalated his public fight over Starlink’s launch in India on Friday, addressing Reliance chairman Mukesh Ambani as “Prime Minister Ambani” in a sarcastic post on X. “Please accept my humble apologies for not realizing that you are the real boss of India,” Musk wrote, before accusing Ambani of “monopolistic exploitation” and asking whether he would “consider allowing Starlink to compete.” In follow up posts, he said Starlink has proven essential during natural disasters and would help parts of India with no internet access.

The post came two days into a fight that Musk sparked up on Wednesday, when he said Starlink was “being blocked by certain oligarchs in order to maintain their monopolistic chokehold on the Indian people.” He called it “a crime against the people of India” and left the names out, adding only, “You can guess who they are.” Jio and Airtel together hold more than 80% of India’s telecom market. On Thursday, Musk asked whether Ambani is “the real boss of India” and said Starlink has spent five years complying with “every single law and requirement” of the Indian government.

India’s government has pushed back each time. The Ministry of Communications called the suggestion that its framework is unfair or discriminatory “baseless and misconceived.” Communications Minister Jyotiraditya Scindia said Friday that three companies hold satcom licenses: Starlink, Jio Satellite Communications, and Bharti backed Eutelsat OneWeb. Amazon’s Kuiper, now Amazon Leo, is still going through the process. None can launch until regulators finalize satellite spectrum pricing and the Home Ministry signs off on each company’s security compliance. Scindia said the telecom regulator and the Department of Telecommunications are close to a decision on pricing, The Hindu reported. Bharti chairman Sunil Mittal also said OneWeb is still waiting on approvals.

Starlink received its operator license in 2025 after a three year wait, and the space regulator IN-SPACe granted what industry executives called the last approval needed in July. The holdup since then centers on security, particularly concern that foreign operators could bypass Indian gateways.

Musk and Ambani have been on opposite sides of this before. In late 2024, Ambani argued for auctioning satellite spectrum, which Musk criticized as out of step with the rest of the world, and India chose administrative allocation instead. By March 2025, the two sides had signed a deal to sell Starlink devices in Reliance stores, and Starlink secured its telecom license that June. That partner is now also a competitor. Jio is reportedly weighing a constellation of 1,600 to 1,650 satellites costing an estimated $10 billion to $15 billion, while Akash Ambani has told shareholders Jio plans to lease capacity from global providers to move quickly.

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Elon Musk’s surprise addition to the X Takeover lineup has fans talking

Elon Musk will join Saturday’s X Takeover at Giga Texas for a live virtual interview.

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Credit: Tesla Owners Silicon Valley
Credit: Tesla Owners Silicon Valley

Elon Musk will join X Takeover at Giga Texas on Saturday for a live virtual interview, according to Sawyer Merritt, who shared the news late Thursday. Musk will not be on stage in Austin. The conversation is set to stream for free on the @teslaownersSV account on X.

Organizers had kept expectations in check. In a September update, Tesla Owners Silicon Valley said Musk had appeared at the event twice before but was not promising a third appearance, even as fans hoped he would walk the Giga Texas grounds in person. A virtual spot matches 2024, when Musk gave a surprise interview of about an hour to the crowd in San Luis Obispo, as Teslarati reported at the time.

This year’s edition is a first in several ways. It is the first X Takeover held outside California and the first at a Tesla facility, with tickets selling out in eight days. Tesla provides the venue, but the event is produced independently by Tesla Owners Silicon Valley. The main event runs from 10 a.m. to 6 p.m. CT, followed by a drone and light show at 9 p.m. Maye Musk is the keynote speaker, Franz von Holzhausen is set for a virtual keynote, and Nicki Minaj is the special guest. Joe Tegtmeyer, whose drone footage Teslarati used to track the Optimus factory steel frame at Giga Texas, is also on the speaker list.

Musk’s interview topics have not been revealed, but the backdrop is busy. Tesla doubled its Cybercab fleet in Austin in late September, and last week Musk explained why Robotaxi hours only moved from 10 p.m. to 11 p.m.. Merritt also reported Thursday that Texas DMV records now show 319 registered Cybercabs, up from 169. NHTSA’s deadline for Tesla’s sworn answers on Cybercab certification is October 30, and Tesla reports third quarter earnings on October 21.

Fans who cannot make it to Austin can watch the livestream on X. Musk tends to say more in unscripted settings than he does in prepared remarks, which is the reason this one is worth having open on Saturday.

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It’s official: SpaceX takes aim at Verizon, AT&T, and T-Mobile

SpaceX is buying 800 MHz spectrum from Grain to turn Starlink Mobile into a carrier.

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Starlink D2D direct to device vs Verizon, AT&T (Concept render by Grok)

SpaceX has agreed to buy a nationwide block of low band wireless spectrum, a deal the company says will let Starlink Mobile operate as a full US carrier rather than a satellite add-on for someone else’s network.

The company announced the agreement on X on Thursday afternoon, saying it will “pave the way for @Starlink to become a major mobile carrier in the US.” The seller is Grain Management, a private investment firm that confirmed in a statement that SpaceX will acquire 100% of its nationwide 800 MHz portfolio. That covers up to 14 MHz of paired spectrum in the 817 to 824 MHz and 862 to 869 MHz bands. Neither side disclosed a price, and the deal still needs FCC approval.

Grain only recently picked up the licenses itself. It bought the portfolio from T-Mobile in a transaction that closed in August, paying cash plus its own 600 MHz spectrum. Rival AST SpaceMobile had been testing satellites on the same bands before SpaceX stepped in.

SpaceX said its 2 GHz spectrum will handle high bandwidth capacity, while the new 800 MHz layer “ensures Starlink Mobile’s signal penetrates through obstacles, such as walls, and can provide service to customers’ devices even when they are in buildings.” The company added that most existing phones already support the band, so customers would not need new hardware to use it.

That 2 GHz spectrum came from SpaceX’s EchoStar acquisition last year, which gave the company exclusive S band rights in the US and global Mobile Satellite Service licenses. The Grain spectrum is different in an important way: it is tailored for service from ground towers, not satellites. SpaceX said that combination would make Starlink Mobile “the first network operator to deploy both satellite and terrestrial spectrum.”

The announcement also follows a key regulatory win. Earlier this week, the FCC approved SpaceX’s plan to deploy 15,000 second generation Starlink Mobile satellites, which the company has said will carry up to 100 times the data density of the current system, as Teslarati previously reported.

Shares of AT&T, Verizon and T-Mobile fell in extended trading after the announcement. T-Mobile is currently SpaceX’s launch partner for Starlink Mobile in the US, which makes its position the most complicated of the three.

SpaceX has not been subtle about its plans. During the company’s August earnings call, President and COO Gwynne Shotwell said she expected Starlink Mobile to win over customers from the major carriers. “I anticipate us to be able to acquire quite a few of their customers because I think our service will be better,” she said, pointing to dead zone coverage and resilience during disasters. Shotwell also described plans for low cost cellular base stations that could pair with existing Starlink dishes.

SpaceX has targeted 2027 for deployment of its next generation Starlink Mobile satellites, with upgraded service expected by the end of that year. The FCC review of the Grain deal now determines when the terrestrial half of that network can come online.

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