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Rocket Lab Electron returns to flight as FAA approves launches from the US

The Rocket Lab Electron on the Launch Complex 2 launch pad at the NASA Wallops Flight Facility. (Rocket Lab)

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Rocket Lab, the space systems company and small satellite launcher, returned to active launch status recently with the successful fourteenth launch of its Electron rocket. The “I Can’t Believe It’s Not Optical” mission marked Rocket Lab’s comeback after suffering an in-flight anomaly during Electron’s thirteenth flight on July 4, 2020.

Just nine weeks after the conclusion of the incident investigation, following its successful return to flight, Rocket Lab has announced that it has been granted a five-year Launch Operator License – permission to launch multiple missions a year – by the Federal Aviation Administration (FAA) for its new Launch Complex 2 in Virginia.

Rocket Lab’s Electron is seen on the launch pad at Launch Complex 2 at NASA’s Wallops Flight Facility during integrated systems tests. (Rocket Lab)

“I Can’t Believe It’s Not Optical,” Electron’s Return to Flight

The thirteenth flight of Electron “Pics or It Didn’t Happen” on July 4 began with a flawless launch from Launch Complex – 1A (LC-1A) in Mahia, New Zealand. During the flight of the second stage, there were indications that Electron had experienced a critical malfunction. Telemetry data confirmed that Electron had encountered an in-flight anomaly that ultimately resulted in the company’s first mission failure and loss of seven customer payloads.

The root cause of the anomaly was quickly tracked down to a single bad electrical connection on the second stage. Less than a month after the incident, Rocket Lab announced that it was able to reconstruct what occurred, make the necessary corrective measures, and ready to return Electron to flight.

Just a few short weeks later on August 24, Electron was on pad LC-1A in New Zealand for pre-flight testing ahead of its fourteenth – and return to flight – mission “I Can’t Believe It’s Not Optical.” The dedicated mission for San Francisco-based information services company, Capella Space, carried a single microsatellite called “Sequoia” to a circular orbit at approximately 500km.

According to a statement provided by Rocket Lab, Sequoia is the “first synthetic aperture radar (SAR) satellite to deliver publicly available data from a mid-inclination orbit over the U.S., Middle East, Korea, Japan, Europe, South East Asia, and Africa.” Sequoia is the first microsatellite in a constellation series that Capella Space says will “provide insights and data that can be used for security, agricultural and infrastructure monitoring, as well as disaster response and recovery.”

The Rocket Lab Electron performs nominally for its return to flight mission “I Can’t Believe It’s Not Optical” from LC-1A in New Zealand. (Rocket Lab)

The success of “I Can’t Believe It’s Not Optical” marks the thirteenth successful mission and the deployment of Sequoia makes a total of 54 satellites delivered to orbit since Rocket Lab began operation in 2017. Rocket Lab founder and chief executive officer, Peter Beck, congratulated Capella Space on the successful deployment of its first microsatellite and celebrated the entire Rocket Lab team stating that “I’m also immensely proud of the team, their hard work, and dedication in returning Electron to the pad safely and quickly as we get back to frequent launches with an even more reliable launch vehicle for our small satellite customers.”

FAA certifies Electron launches from the US

In addition to LC-1A in New Zealand, Rocket Lab broke ground on a second launchpad located in the United States in late 2018. The launchpad was declared complete in December 2019.

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Although operational, Launch Complex 2 located at the Mid-Atlantic Regional Spaceport within NASA’s Wallops Flight Facility on Wallops Island in Virginia still had a few milestones to achieve ahead of the first scheduled launch. In April 2020 an Electron rocket arrived at the pad for integrated systems tests. Two major hurdles left to clear ahead of launching an Electron from LC-2 was receiving a launch operator license from the Federal Aviation Administration (FAA) and receiving NASA certification of the Electron’s Autonomous Flight Termination System (AFTS).

On Tuesday, September 1, Rocket Lab announced that it had received a new 5-year Launch Operator License from the FAA. The license permits California-based launcher and space systems company to launch the Electron rocket from LC-2 multiple times a year without applying for a new license with every launch. This in addition to the Launch Complex 1 license means that Rocket Lab is now licensed to support up to 130 flights of Electron per year.

In addition, LC-1 is expected to expand and bring a second launchpad online, launch complex – 1B, sometime before the end of the year. Beck said, “Having FAA Launch Operator Licenses for missions from both Rocket Lab launch complexes enables us to provide rapid, responsive launch capability for small satellite operators. With 14 missions already launched from LC-1, Electron is well established as the reliable, flight-proven vehicle of choice for small sat missions spanning national security, science and exploration.”

Launch Complex 2 was specifically designed to support responsive missions for NASA and the United States government. The first mission from LC-2 is slated to lift the microsatellite STP-27RM for the United States Air Force as part of the Space Test Program. In 2021 Electron will send NASA’s CAPSTONE mission to a “Near Rectilinear Halo Orbit” (NRHO) around the Moon in support of NASA’s Artemis program.

Even more news…

On Thursday, September 3, Rocket Lab founder Peter Beck will host a webcast to provide an “exciting update” and discuss “the next chapter” of Rocket Lab. The webcast will go live at 2:00 pm ET (18:00UTC).

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

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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