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SpaceX aces 60th operational Starlink launch after string of scrubs

(Richard Angle)

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SpaceX has completed its 60th operational Starlink satellite launch after a rare string of scrubs.

Flying for the 6th time just 66 days after its 5th launch, Falcon 9 booster B1067 lifted off with 54 Starlink satellites on SpaceX’s Starlink 4-34 mission at 8:18 pm EDT, Sunday, September 18th. Five days prior, after unknown issues triggered a delay from a planned September 11th launch attempt, SpaceX attempted to launch the mission for the first time on September 13th.

About an hour before liftoff, lightning conditions forced the company to call off the attempt. On September 14th, also about an hour before liftoff, weather forced SpaceX to call off the second attempt. On September 15th, the third attempt was aborted (by weather) just 29 seconds before liftoff, followed by a fourth weather-related scrub about a minute before liftoff on September 16th. Only after a fifth attempt on September 17th was preempted by a delay to September 18th did SpaceX finally find a gap between Florida’s summer weather.

With dozens of Starlink launches beginning to blur together and SpaceX’s Falcon 9 continuing a relentless and potentially record-breaking streak of successes at a pace that could soon make it the fastest launching rocket in history, it’s hard to be surprised that Starlink 4-34 was completed without issue. Falcon 9 B1067 ascended under power for about three minutes, sent the rest of the rocket on the way to orbit, coasted into space, and returned to Earth with SpaceX’s 68th consecutively successful booster landing.

Falcon 9’s underappreciated upper stage continued into an orbit around 300 kilometers (~190 mi) up, spun itself up end over end, and deployed a 16.7-ton (~36,900 lb) stack of 54 Starlink V1.5 satellites all at once. Following the quick deployment, the rocket’s pair of reusable fairing halves were likely still 10 or 20 minutes away from touching down on the Atlantic Ocean under their GPS-guided parafoils, where they will eventually be scooped out of the water for future flights.

Starlink 4-34 was SpaceX’s 42nd launch of 2022, maintaining an average of one launch every 6.2 days since the year began. It leaves more than 3000 working Starlink satellites in Earth orbit, likely meaning that a majority of all working satellites are owned and operated by SpaceX less than three full years after the company began operational launches.

Up next, Next Spaceflight and Spaceflight Now report that SpaceX has two more Starlink launches (4-35 and 4-36) tentatively scheduled before the end of September. As of September 15th, both reported that those missions were working towards launches on September 19th and September 26th – nothing unusual for SpaceX in 2022.

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What was unusual, however, was both unofficial manifests’ agreement that SpaceX intended to use the same pad – Cape Canaveral Space Force Station’s LC-40 – to launch Starlink 4-34, 4-35, and 4-36. Even assuming that those schedules were predicated upon Starlink 4-34 launching on September 13th, before all of its weather delays, SpaceX would have had to break LC-40’s 7.7-day turnaround record by around ~25% and complete a second launch just seven days after that.

Starlink 4-34’s delays have thrown that plan into question, but the fact that SpaceX thought it was possible in the first place suggests that the company has plans to squeeze even more performance out of LC-40 – already its most important pad from the perspective of launch cadence. Launch photographer Ben Cooper now reports that Starlink 4-36 could launch in late September or October. If it slips into October, SpaceX has a rapid-fire pair of customer satellite launches scheduled on October 5th and 13th that will probably take precedent over any internal Starlink mission.

With only 16 days left before LC-40’s next commercial launch and NASA’s Crew-5 launch taking over SpaceX’s other East Coast pad until October 3rd, SpaceX would have to launch Starlink 4-35 and 4-36 just four or five days apart (and one just 4-5 days after Starlink 4-34) to avoid delaying one of the Starlink missions well into October, avoid unnecessarily delaying commercial launches for paying customers, and ensure that those customers don’t have abruptly agree to be commercial guinea pigs for extra quick LC-40 turnarounds.

Starlink 4-35 is now tentatively scheduled for September 23rd, making a Starlink 4-36 delay more likely but not fully ruling out a launch attempt before the end of the month.

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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Cybertruck

Tesla Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

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

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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Elon Musk

SpaceX has solved Starship’s biggest challenge, Elon Musk says

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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