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DeepSpace: Rocket Lab nails third Electron launch of 2019 as next rocket heads to launch pad

Rocket Lab's Electron rocket lifts off from Mahia Peninsula on June 29th for the company's third launch of 2019. (Rocket Lab)

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Welcome to the latest edition of DeepSpace! Each week, I’ll hand-craft this newsletter to give you a breakdown of what’s happening in the space industry and tell you what you need to know. 

On June 29th, startup Rocket Lab completed its third successful Electron rocket launch this year, placing roughly half a dozen small(ish) satellites in orbit as part of a dedicated mission for Seattle-based startup Spaceflight Industries.

Technically speaking, with three launches under its belt, Rocket Lab has now reached orbit more times this year than the United Launch Alliance’s (ULA) Atlas V and Delta IV rockets combined, despite the fact that the company conducted its first commercial launch just seven months ago. In other words, Rocket Lab is finding its stride with Electron at an unprecedented speed and may be able to complete its tenth successful orbital launch less than two years after the company first reached orbit (January 2018). June 29th’s launch is just the latest in a string of impressive successes for Rocket Lab and the company doesn’t appear to be slowing down any time soon.



Electron Flight 7: “Make It Rain”

  • A tongue-in-cheek reference to the stereotype that it rains constantly in Seattle, home of launch contractor Spaceflight Industries, Electron Flight 7 was a commercial rideshare mission that included six publicly manifested satellites and at least one classified payload.
    • Altogether, the payload mass was reported by Rocket Lab to be roughly 80 kg (175 lb). Aside from marking the orbital debut of Australia’s Melbourne Space Program, Flight 7’s main passenger – manifested via SpaceX – was BlackSky’s ~56 kg (125 lb), dishwasher-sized Global 3 satellite, the third of its kind to reach orbit.
    • BlackSky’s ultimate goal is to build a full constellation of at least 60 Global satellites, each capable of delivering >1000 images with an impressive resolution of ~1m/pixel. The first four (including Global 3) were actually built by Spaceflight itself, but the 60-satellite constellation is to be produced at LeoStella’s recently-inaugurated Seattle factory and replaced every few years.
 

Attached above black, rectangular cubesat dispensers is BlackSky’s minifridge-sized Global 3 satellite (top), encapsulated inside Electron’s carbon fiber fairing soon after (left). Electron lifted off (right) on June 28th (June 29th local time) and was greeted by a spectacular sunset-lit view of its launch site, located on New Zealand’s Mahia Peninsula. (Rocket Lab)

  • It can be all but guaranteed that BlackSky (or LeoStella) will return to Rocket Lab for future Global satellite launch contracts, perhaps flying 2-3 spacecraft at a time to expedite constellation completion and lower the overall cost of getting it into orbit.
  • Carrying a price tag of roughly $6M, Electron is capable of placing 150 kg (330 lb) into a 500 km (310 mi) sun-synchronous orbit (SSO). 3 Global satellites would likely push Electron to its limits, while 2 would leave plenty of space for additional copassenger spacecraft and thus opportunities to lower the overall cost to BlackSky.
  • Some 50 minutes after lifting off from New Zealand, Electron’s third stage – a “kick stage” powered by a custom-built Curie engine – ignited and burned for about 45 seconds, circularizing its orbit. A few minutes later, all 6-7+ spacecraft were successfully deployed, leaving the kick stage to once again lower its orbit to facilitate a quick and controlled reentry, minimizing space debris.

Onto the next one

  • Pictured at the bottom of the gallery above, Rocket Lab – much like SpaceX – completed a full static fire test of Flight 8’s Electron upper stage, the last major test milestone standing in the way of Electron’s next launch. Located in Auckland, NZ, the upper stage will now be shipped around 300 mi (500 km) south to Rocket Lab’s Mahia Peninsula-based Launch Complex 1 (LC-1).
  • According to Rocket Lab’s website, Electron Flight 8 is scheduled no earlier than (NET) August 2019, although the company’s Flight 7 webcast host indicated that it could happen as early as July.
    • Either way, it appears that Rocket Lab is well on its way to achieving a bimonthly average launch cadence this year.
    • The company’s goal is to reach a monthly launch cadence by the end of the year, roughly halving its current 2019 average of ~50 days between launches.
  • Ultimately, Rocket Lab’s future continues to look brighter month by month. As the only commercial smallsat launch operator currently serving customers, the company is essentially early to the party and has the market cornered by simply being first. Every launch will provide experience and get the company closer to profitability and even greater launch cadences, perhaps as high as 2-3x per month by the end of 2020.
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– Eric

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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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.

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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.

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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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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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