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Rocket Lab briefly catches Electron booster with a helicopter on first try
In a significant achievement, public launch provider Rocket Lab has – with a few caveats – successfully used a helicopter to catch the booster of its Electron rocket out of mid-air on the very first attempt.
The company began working on ways to recover and reuse the booster of its tiny Electron rocket in 2019, going back on a promise repeatedly made by founder and CEO Peter Beck in the years prior. Due to just how small the Electron rocket is, it was generally assumed that Beck wasn’t wrong to avoid attempting to recover or reuse its parts of it. However, that attitude quickly changed when the need to ramp up launch cadence became a leading priority. Soon after, Beck revealed that Rocket Lab engineers had looked more carefully at the problem and concluded that Electron booster recovery was more feasible than assumed.
Once the problem was no longer deemed insurmountable, the allure of reuse – intrinsically multiplying the effectiveness of any given production line if done right – was irresistible.
While the change in attitude made Rocket Lab the second company after SpaceX to begin seriously developing the ability to recover and reuse orbital-class liquid rocket boosters, the approach it would need to take for a rocket as small as Electron was almost nothing like that used by Falcon boosters. Instead of multiple in-flight engine ignitions, supersonic retropropulsion, steerable fins, and a propulsive landing, Electron would rely on several parachutes to slow itself down, use small thrusters (not unlike Falcon) for attitude control, and be actively captured out of mid-air by a crewed helicopter.
Ironically, demonstrating the sheer size gap between Electron and Falcon 9, Electron booster recovery more closely resembles Falcon 9 fairing recovery. Weighing in at around one ton (~2200 lb) per half, or about as heavy as an entire Electron rocket booster, each fairing half mainly just controls its attitude with cold-gas thrusters while passively reentering Earth’s atmosphere. Fairing halves then deploy a GPS-guided parafoil and gently splash down on the ocean surface before being fished out of the water by a waiting ship.
That is exactly how Rocket Lab trialed Electron recovery on several prior attempts, fishing intact boosters out of the Pacific Ocean after gentle ocean landings. For a while, SpaceX even attempted to catch fairings out of mid-air – albeit with a highly-modified ship and net instead of a helicopter and hook. However, when the company realized it could easily reuse fairing halves that landed in the ocean, it fully abandoned catch attempts.
In Electron’s case, it’s no surprise that Rocket Lab still pursued catch-based recovery while SpaceX was simultaneously giving up on the practice. Put simply, it would be incredibly difficult to reliably and affordably reuse a liquid rocket booster – and liquid rocket engines especially – after dunking them in saltwater.
That’s also why the success of Rocket Lab’s first operational catch attempt has caveats. While the company did successfully catch the booster out of mid-air, the pilot – who holds final authority for the sake of safety – observed unusual behavior not seen during testing after hooking Electron and chose to release the booster early. Thankfully, it still managed a soft landing in the ocean and was recovered by ship, but despite statements from Beck to the contrary, that seawater exposure will almost certainly make it impossible to fully reuse. To call the attempt a total success, the helicopter would have needed to drop the booster off on the recovery ship’s deck, fully avoiding a bath.
Above all else, even if the catch didn’t last, Rocket Lab successfully launched 34 small satellites and payloads into orbit for several paying customers and briefly caught the booster that launched them with a helicopter. The attempt was arguably far more successful than not and likely leaves Rocket Lab just a little more practice and a few small optimizations away from a perfect recovery. Then the company can shift its focus to the next goal: the first Electron booster reuse.
News
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years.
The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Dry cathode 4680 cells
In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.
The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”
Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.
4680 packs for Model Y
Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla:
“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”
The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.
Elon Musk
Tesla Giga Texas to feature massive Optimus V4 production line
This suggests that while the first Optimus line will be set up in the Fremont Factory, the real ramp of Optimus’ production will happen in Giga Texas.
Tesla will build Optimus 4 in Giga Texas, and its production line will be massive. This was, at least, as per recent comments by CEO Elon Musk on social media platform X.
Optimus 4 production
In response to a post on X which expressed surprise that Optimus will be produced in California, Musk stated that “Optimus 4 will be built in Texas at much higher volume.” This suggests that while the first Optimus line will be set up in the Fremont Factory, and while the line itself will be capable of producing 1 million humanoid robots per year, the real ramp of Optimus’ production will happen in Giga Texas.
This was not the first time that Elon Musk shared his plans for Optimus’ production at Gigafactory Texas. During the 2025 Annual Shareholder Meeting, he stated that Giga Texas’ Optimus line will produce 10 million units of the humanoid robot per year. He did not, however, state at the time that Giga Texas would produce Optimus V4.
“So we’re going to launch on the fastest production ramp of any product of any large complex manufactured product ever, starting with building a one-million-unit production line in Fremont. And that’s Line one. And then a ten million unit per year production line here,” Musk stated.
How big Optimus could become
During Tesla’s Q4 and FY 2025 earnings call, Musk offered additional context on the potential of Optimus. While he stated that the ramp of Optimus’ production will be deliberate at first, the humanoid robot itself will have the potential to change the world.
“Optimus really will be a general-purpose robot that can learn by observing human behavior. You can demonstrate a task or verbally describe a task or show it a task. Even show it a video, it will be able to do that task. It’s going to be a very capable robot. I think long-term Optimus will have a very significant impact on the US GDP.
“It will actually move the needle on US GDP significantly. In conclusion, there are still many who doubt our ambitions for creating amazing abundance. We are confident it can be done, and we are making the right moves technologically to ensure that it does. Tesla, Inc. has never been a company to shy away from solving the hardest problems,” Musk stated.
Elon Musk
Rumored SpaceX-xAI merger gets apparent confirmation from Elon Musk
The comment follows reports that the rocket maker is weighing a transaction that could further consolidate Musk’s space and AI ventures.
Elon Musk appeared to confirm reports that SpaceX is exploring a potential merger with artificial intelligence startup xAI by responding positively to a post about the reported transaction on X.
Musk’s comment follows reports that the rocket maker is weighing a transaction that could further consolidate his space and AI ventures.
SpaceX xAI merger
As per a recent Reuters report, SpaceX has held discussions about merging with xAI, with the proposed structure potentially involving an exchange of xAI shares for SpaceX stock. The value, structure, and timing of any deal have not been finalized, and no agreement has been signed.
Musk appeared to acknowledge the report in a brief reply on X, responding “Yeah” to a post that described SpaceX as a future “Dyson Swarm company.” The comment references a Dyson Swarm, a sci-fi megastructure concept that consists of a massive network of satellites or structures that orbit a celestial body to harness its energy.
Reuters noted that two entities were formed in Nevada on January 21 to facilitate a potential transaction for the possible SpaceX-xAI merger. The discussions remain ongoing, and a transaction is not yet guaranteed, however.
AI and space infrastructure
A potential merger with xAI would align with Musk’s stated strategy of integrating artificial intelligence development with space-based systems. Musk has previously said that space-based infrastructure could support large-scale computing by leveraging continuous solar energy, an approach he has framed as economically scalable over time.
xAI already has operational ties to Musk’s other companies. The startup develops Grok, a large language model that holds a U.S. Department of Defense contract valued at up to $200 million. AI also plays a central role in SpaceX’s Starlink and Starshield satellite programs, which rely on automation and machine learning for network management and national security applications.
Musk has previously consolidated his businesses through share-based transactions, including Tesla’s acquisition of SolarCity in 2016 and xAI’s acquisition of X last year. Bloomberg has also claimed that Musk is considering a merger between SpaceX and Tesla in the future.
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
Tesla Giga Texas to feature massive Optimus V4 production line
