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SpaceX’s next Falcon Heavy hits milestone as final rocket parts arrive in Florida

SpaceX has all the components needed for Falcon Heavy's third launch, set to lift off as early as June 22nd. (USAF)

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SpaceX has reached a critical milestone on the road to Falcon Heavy’s third flight: all major parts of the rocket – three boosters, an interstage, and a payload fairing – are now officially on-site at the company’s Pad 39A launch facilities.

This means that all that stands between SpaceX, the USAF, and the critical mission is the integration of the hardware into one vehicle, as well as the integration and encapsulation of all 24 customer satellites in the Falcon payload fairing. As noted by the USAF Space and Missile Systems Center (SMC), Falcon Heavy’s Space Test Program-2 (STP-2) mission will be exceptionally challenging and important for SpaceX for a variety of reasons.

Falcon Heavy: The Upper Stagening

Although the general performance of the three first stage boosters will be absolutely critical, the US Air Force’s STP-2 mission manages to cram in several additional major goals. First and foremost, all eyes will be on SpaceX’s Falcon upper stage (S2). Scheduled to last no less than several hours, the upper stage will be put through its paces like never before, requiring four separate ignitions and shutoffs of its Merlin Vacuum engine. For SpaceX, this may be the first time the company has ever attempted the feat – if any on-orbit testing has been done after completing customer missions, SpaceX has never commented on it.

Back in February 2018, Falcon Heavy’s launch debut also happened to mark the first flight-test of a true long-duration upper stage coast and third ignition, a spectacular success that sent Starman and a Tesla Roadster into a heliocentric orbit that now reaches beyond Mars. As such, SpaceX will by no means be walking into the challenges of STP-2 unprepared. In fact, the coast required on Flight 1 may have technically been more challenging than any one of the four separate burns S2 will need to perform on STP-2. However, combining the need to do all four burns and deployments rather quickly and in sequence, the critical need for accurate orbital insertions, and high standards of reliability and mission assurance expected by the USAF, STP-2 will easily be the hardest mission SpaceX has yet to attempt.

SpaceX's Falcon Heavy debut likely relied in part upon Tesla battery tech for second stage's nearly six hour-long coast before sending Starman beyond Earth orbit. (SpaceX)
SpaceX’s first Falcon Heavy launch also happened to be a strategic and successful test of Falcon upper stage coast capabilities. (SpaceX)

If SpaceX succeeds, the benefits will stretch far beyond simply satisfying an Air Force requirement and securing the USAF’s Falcon Heavy certification. Once SpaceX has rigorously demonstrated the reliability of Falcon 9’s upper stage for long coasts and high numbers of ignition events, the company will be able to apply that as a marketable product. Potential customers include the usual communications satellite operators desiring a direct-to-GEO insertion, saving time (and thus making money faster) by skipping the orbit-raising that comes with easier transfer orbits.

One major use-case – as demonstrated by Falcon Heavy’s interplanetary launch debut – is sending payloads beyond Earth orbit, a capability that NASA would undoubtedly take advantage of.

Reusability makes a surprise entrance

But wait, there’s more! In a predictable but still largely unexpected turn of events, the Air Force has also selected Falcon Heavy’s STP-2 mission as an opportunity to gain familiarity with the rocket reusability SpaceX is famous for. Falcon Heavy’s second mission and commercial launch debut – Arabsat 6A – used three all-new Block 5 boosters, two of which returned to land after gentle recoveries. Known as B1052 and B1053, the lightly-used boosters are now scheduled to become the first flight-proven orbital-class rockets launched on a Department of Defense (DoD) mission in 25 years, since the Space Shuttle’s final military mission in 1992.

If successful, SpaceX will help pave the way for the US military to seriously adopt reusable rockets and develop the “certification” procedures needed to do so. This will benefit all prospective US launch providers, not just SpaceX, but SpaceX will likely be the only company flying valuable payloads on flight-proven rockets until Blue Origin and ULA’s Vulcan achieve flight-proven certification for military launches. Much like regular certification often requires multiple launch demonstrations, flight-proven certification will likely be at least as – if not more – stringent. For New Glenn, that milestone might come as early as 2023-2025, while Vulcan – if a reusable engine section is ever actually implemented – is unlikely to even complete its launch debut – let alone first reuse – before 2025.

As such, SpaceX is quite literally half a decade ahead of its prospective competitors when it comes to certifying flight-proven rockets for high-value launches. Additionally, just the act of the USAF completing its development of a reusability certification process will likely encourage – if not directly lay the foundation for – NASA to seriously consider doing the same with its own launch services.

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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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Tesla Model X lost 400 pounds thanks to these changes

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Credit: Tesla

The Tesla Model X has always been one of the company’s most loved vehicles, despite its low sales figures, which can be attributed to its high price tag.

However, the Model X has been a signature item on Tesla’s menu of cars, most notably recognized by its Falcon Wing Doors, which are aware of its surroundings and open according to what’s around it.

But recent improvements to the Model X were looking slim to none, but it appears most of the fixes actually happened under the body, at least according to Tesla’s Vice President of Powertrain, Lars Moravy.

In a recent interview with Car and Driver, Moravy detailed all of the changes to the 2026 iteration of the vehicle, which was about 400 pounds lighter than it was originally. The biggest change is a modification with the rear motor, switching from an induction-type motor to a permanent-magnet design and optimizing the half-shafts, which shed about 100 pounds.

Tesla also got “almost 80 pounds out of the interior bits and pieces,” which “included making parts thinner, different manufacturing process choices, and incorporating airbag-deployment requirements into the headliner fabric,” the report said.

Additionally, the standard five-passenger, bench seat configuration saved 50 pounds by ditching pedestal mounting. This also helped with practicality, as it helped the seat fold flat. Engineers at Tesla also saved 44 pounds from the high-voltage wiring through optimizing the wiring from the charge-port DC/DC converter and switching from copper to aluminum wiring.

Tesla makes a decision on the future of its flagship Model S and Model X

Tesla also simplified the cooling system by reducing the number of radiators. It also incorporated Nürburgring cooling requirements for the Plaid variant, which saved nearly 30 pounds.

Many Tesla fans will be familiar with the megacastings, manufactured in-house by presses from IDRA, which also saves more than 20 pounds and boosts torsional stiffness by around 10 percent. Tweaks to the suspension also saved 10 pounds.

People were truly disappointed with what Tesla did with the Model S and Model X, arguing that the cars needed a more severe exterior overhaul, which might be true. However, Tesla really did a lot to reduce the weight of the vehicle, which helps increase range and efficiency. According to Grok, every 200 pounds removed adds between 7 and 15 percent to range estimations.

This makes sense considering the range estimations both increased by 7 percent from the Model X’s 2025 configuration to the 2026 builds. Range increased on the All-Wheel-Drive trim from 329 miles to 352 miles, while the Plaid went from 314 miles to 335 miles.

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Tesla launches its new branded Supercharger for Business with first active station

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Credit: Tesla

Tesla has officially launched its first branded Supercharger just months after initiating a new program that allows third-party companies to brand their own charging piles.

The site opened in Land O’ Lakes, Florida, and features eight V4 Supercharging stalls offering up to 325 kW of charging speed. It appears it was purchased by a company called Suncoast Credit Union. This particular branch is located Northeast of Tampa, which is on the Gulf of Mexico.

It features graphics of Florida animals, like alligators:

Tesla launched this program back in September, and it basically was a way to expand its Supercharger presence and also allow companies to pay for the infrastructure. Tesla maintains it. When it announced the “Supercharger for Business,” it said:

“Purchase and install Superchargers at your business. Superchargers are compatible with all electric vehicles, bringing EV drivers to your business by offering convenient, reliable charging.”

The program does a few things. Initially, it expands EV charging infrastructure and makes charging solutions more readily available for drivers. It can also attract people to those businesses specifically.

Tesla launches new Supercharger program that business owners will love

The chargers can also be branded with any logo that the business chooses, which makes them more personalized and also acts as an advertisement.

The best part is that the customers do not have to maintain anything about the Supercharger. Tesla still takes care of it and resolves any issues:

“We treat your site like we treat our sites. By providing you with a full-service package that includes network operations, preventative maintenance, and driver support, we’re able to guarantee 97% uptime–the highest in the industry.”

It appears the Superchargers will also appear within the in-car nav during routing, so they’ll be publicly available to anyone who needs to use them. They are still available to all EVs that have worked with Tesla to utilize its infrastructure, and they are not restricted to people who are only visiting the business.

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Tesla reveals its Cybertruck light bar installation fix

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u/Kruzat, see page for license, via Wikimedia Commons

Tesla has revealed its Cybertruck light bar installation fix after a recall exposed a serious issue with the accessory.

Tesla and the National Highway Traffic Safety Administration (NHTSA) initiated a recall of 6,197 Cybertrucks back in October to resolve an issue with the Cybertruck light bar accessory. It was an issue with the adhesive that was provided by a Romanian company called Hella Romania S.R.L.

Tesla recalls 6,197 Cybertrucks for light bar adhesive issue

The issue was with the primer quality, as the recall report from the NHTSA had stated the light bar had “inadvertently attached to the windshield using the incorrect surface primer.”

Instead of trying to adhere the light bar to the Cybertruck with an adhesive, Tesla is now going to attach it with a bracketing system, which will physically mount it to the vehicle instead of relying on adhesive strips or glue.

Tesla outlines this in its new Service Bulletin, labeled SB-25-90-001, (spotted by Not a Tesla App) where it shows the light bar will be remounted more securely:

The entire process will take a few hours, but it can be completed by the Mobile Service techs, so if you have a Cybertruck that needs a light bar adjustment, it can be done without taking the vehicle to the Service Center for repair.

However, the repair will only happen if there is no delamination or damage present; then Tesla could “retrofit the service-installed optional off-road light bar accessory with a positive mechanical attachment.”

The company said it would repair the light bar at no charge to customers. The light bar issue was one that did not result in any accidents or injuries, according to the NHTSA’s report.

This was the third recall on Cybertruck this year, as one was highlighted in March for exterior trim panels detaching during operation. Another had to do with front parking lights being too bright, which was fixed with an Over-the-Air update last month.

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