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SpaceX assembles Falcon Heavy rocket for first launch in 40 months

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3 years ago

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SpaceX has assembled the fourth Falcon Heavy for the rocket’s first launch in 40 months.

A photo shared by SpaceX on October 23rd shows that it has mated Falcon Heavy’s three first stage boosters together while preparing for prelaunch testing. Simultaneously, workers have completed the equally important task of converting 39A’s transporter/erector (T/E), which has been configured for single-core Falcon 9 rockets for over three years.

The transporter/erectors SpaceX use for all Falcon launches are a bit like a mobile backbone and launch tower combined. Their first purpose is to transport horizontal Falcon rockets to and from their integration hangars and launch pads. They’re also tasked with raising Falcon rockets vertical and lowering them back down for transport or worker access. Most importantly, they connect to a pad’s ground systems and distribute propellant, gases, power, and communications to Falcon 9 and Falcon Heavy through multiple umbilicals and quick-disconnect ports.

Falcon Heavy, which can only be launched out of LC-39A, has three times as many boosters as Falcon 9 and necessitates significant modifications to the pad’s T/E when switching between the two. The process is much harder when moving from F9 to FH, and waiting almost three and a half years between Falcon Heavy launches likely hasn’t made the conversion any easier. But on October 23rd, after numerous tests and weeks of work, the Pad 39A T/E picked up the ‘reaction frame’ that attaches to the bottom of Falcon rockets and was brought horizontal.

Thanks to the nature of Falcon Heavy and Pad 39A’s infrastructure, what happens next is more or less guaranteed. During normal Falcon 9 operations, 39A’s integration hangar is large enough for two or three unrelated Falcon boosters to remain while the T/E rolls inside to pick up a full Falcon 9. More importantly, Falcon 9’s booster and upper stage can technically be integrated off to the side and craned onto the T/E when ready. But with Falcon Heavy, which has a first stage akin to three Falcon 9 boosters sitting side by side, there isn’t enough room inside the hangar to integrate the rocket with the T/E inside.

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For Falcon Heavy, the T/E can thus only roll back into the hangar once the rocket’s three boosters and upper stage have been fully assembled and are suspended in mid-air. SpaceX’s October 23rd photo shows that three of the four cranes required for that lift appear to already be in position, further confirming that T/E rollback is imminent. Once the T/E rolls back to the hangar and Falcon Heavy is attached, the rocket will eventually be transported to the pad and brought vertical for wet dress rehearsal (WDR) and static fire testing.

Update: SpaceX began rolling the T/E to Pad 39A’s integration hangar around 1 am EDT, October 24th.

The US Space Force’s USSF-44 payload – a mysterious pair of satellites that are more than two years behind schedule – will almost certainly not be installed on Falcon Heavy during prelaunch testing, so the rocket will need to roll back to the hangar at least one more time after testing to have its payload fairing attached.

Combined, that prelaunch process could easily take a week or more. Multiple sources report that Falcon Heavy is scheduled to launch no earlier than (NET) 9:44 am EDT (13:44 UTC) on Halloween, October 31st. But even if the rocket rolls out today (Oct 24), the odds are stacked against Falcon Heavy sailing through its first integrated prelaunch tests in 40 months, and delays are likely.

Falcon Heavy’s fourth flight should look a lot like its second, which also used all-new Block 5 boosters. (Richard Angle)

For Falcon Heavy’s fourth launch, all three of the rocket’s boosters – B1064, B1065, and B1066 – are new, as are its upper stage and payload fairing. An FCC permit for the launch has confirmed that SpaceX will intentionally expend the rocket’s new center core while its twin side boosters will attempt a near-simultaneous landing back at Cape Canaveral. USSF-44 will be SpaceX’s first attempted launch directly to geostationary orbit (GEO), an exceptionally challenging mission that requires the rocket’s upper stage to coast in space for around 4-6 hours between two major burns.

If successful, Falcon Heavy will insert the USSF-44’s mystery satellites into a circular orbit ~35,600 kilometers (~22,150 mi) above Earth’s surface. At that altitude, orbital velocity matches Earth’s rotation and spacecraft can effectively hover – indefinitely – above their region of choice.

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Falcon Heavy is the most powerful operational rocket in the world. At liftoff, it weighs around 1420 tons (~3.1M lb) and can produce more than 2300 tons (~5.1M lbf) of thrust. In a fully expendable configuration, Falcon Heavy can launch 26.7 tons (59,000 lb) to an elliptical geostationary transfer orbit and 63.8 tons (141,000 lb) to low Earth orbit. SpaceX doesn’t advertise its direct-to-GEO capabilities.

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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 Robotaxi test units spotted in new region ahead of launch

These validation units are used to gain additional data for Tesla’s internal use, or even potentially for regulatory purposes that the company can share with agencies that will eventually grant a license to operate Robotaxi in the state.

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31 minutes ago

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October 31, 2025

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Credit: @MWraps30584 | X

Tesla Robotaxi test units are being spotted in various new regions ahead of their launch in new states. Tesla is aiming to launch in at least a few new states in the coming months as it is ramping up hiring for the Robotaxi program and aiming to expand its ride-hailing service.

Already active in Austin, Texas, and the California Bay Area, Tesla is looking to expand its Robotaxi operations to new states. It’s had its eyes set on Nevada, Florida, and Arizona, which have seemed to have the most movement of the three prospects over the past month or so.

That trend is continuing.

Earlier this month, we reported on two Robotaxi units spotted testing with LiDAR rigs for ground truth validation in Gilbert, Arizona. Noted Cybertruck owner and enthusiast Greggertruck spotted the two units traveling on a highway.

Tesla Robotaxi testing in Arizona is ramping up quickly

Now, those same two units, or at least they appear to be, were spotted in Scottsdale, which is also a suburb of Phoenix, like Gilbert is, with the same LiDAR rigs:

These validation units are used to gain additional data for Tesla’s internal use, or even potentially for regulatory purposes that the company can share with agencies that will eventually grant a license to operate Robotaxi in the state.

Tesla is not a company that utilizes LiDAR for its everyday self-driving efforts, as it has utilized only cameras for the past several years.

Tesla Vision, as the company calls it, is what CEO Elon Musk feels is needed to achieve a fully autonomous network of vehicles, which will eventually need zero supervision for passenger transportation.

LiDAR is utilized by other companies, like Waymo, but Tesla has maintained that it is not necessary for several years. Musk has called it a “crutch” for achieving the proper self-driving tech, and the company only uses it for an additional bit of data.

Tesla has been operating its Robotaxi service in Austin since late June, and it has expanded its service area in the city to nearly 300 square miles, with its most recent expansion occurring earlier this week.

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Elon Musk

Tesla’s popular side business is going to get bigger, Elon Musk says

It took several years to get the Diner developed, built, and opened. On July 21, Tesla launched the Diner to the public at 4:20 p.m. local time (of course), after years of development. Musk first offered the idea of a drive-in Supercharger Diner back in December 2018.

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2 hours ago

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October 31, 2025

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tesla diner in los angeles during daytime
Credit: Matt Hartman

Tesla will open two new Diner locations in the United States after its first location in Los Angeles has been a raging success, as it is constantly packed and serving food for 24 hours a day, every day.

Tesla CEO Elon Musk said that the initial Diner location on Santa Monica Boulevard is “going well,” and based on reviews and its constant out-the-door lines, it is safe to say it has been a major outlet of interest for people in the area.

It features two massive movie screens, a menu that is locally sourced and has been created by a world-class chef, and Supercharging for EVs. It truly is the perfect stop for those who are hungry, need entertainment, or need a quick charge.

tesla diner

Credit: Tesla

So far, Tesla has not released too many details on the success of the restaurant, but it did state in a graphic for its Q3 Supercharging stats that it sold roughly 50,000 burgers at the Diner in Q3, roughly 715 each day. Burgers are not the only thing on the menu, either.

With how well it has gone, Musk is now considering the possibility of new locations that are notable to Tesla, including Austin and Palo Alto.

On Friday, Musk revealed he believes it “probably makes sense to open one” near Gigafactory Texas and Engineering HQ in Palo Alto:”

It took several years to get the Diner developed, built, and opened. On July 21, Tesla launched the Diner to the public at 4:20 p.m. local time (of course), after years of development. Musk first offered the idea of a drive-in Supercharger Diner back in December 2018.

By 2023, Tesla had secured building permits and broken ground on the site in September of that year.

Since its launch, it has been a popular hotspot for Tesla fans and others to visit, although it has attracted unwanted attention from protestors as well.

They look hungry. If they walked inside and ordered some food, maybe they’d stop yelling into microphones and threatening Musk.

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Elon Musk

Elon Musk’s AI empire grows as xAI leases Palo Alto space near Tesla

The expanding footprint of Elon Musk’s companies in Palo Alto bodes well for the CEO’s plans in the area.

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4 hours ago

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October 31, 2025

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Credit: xAI/X

Elon Musk’s artificial intelligence startup, xAI, is expanding its Silicon Valley footprint, leasing roughly 105,000 square feet of office space at Palo Alto’s Page Mill Center, just blocks away from Tesla’s engineering complex.

Musk’s deepening Silicon Valley footprint

People familiar with the matter have informed the San Francisco Business Times that xAI’s lease at Page Mill Center may already have been finalized, adding to the company’s existing headquarters at 1450 Page Mill Road. The two offices share a parking lot, reflecting Musk’s strategy of consolidating his ventures. Tesla’s engineering hub is also just a few blocks away.

The new offices form a growing cluster of Musk-led companies in the heart of the Valley and come as xAI has listed over 250 job openings. These include listings for engineers, designers, and technical staff, among others. 

xAI’s aggressive hiring push hints at rapid scaling, which makes quite a lot of sense considering the company’s ambitious projects. xAI oversees the large language model Grok and other AI initiatives such as the newly launched Grokipedia, and the startup has also acquired the social media platform X. Real estate owner Hudson Pacific Properties, the owners of Page Mill Center, have so far declined to comment.

AI demand and Silicon Valley’s office rebound

Silicon Valley’s office market, long subdued by remote work trends, is seeing renewed activity from AI firms. Hudson Pacific told investors this summer that tenant demand has reached a three-year high, with over half of new leases driven by artificial intelligence companies. Vacancy rates have now fallen for four straight quarters to 16.6% as well, CBRE reported.

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The expanding footprint of Elon Musk’s companies in Palo Alto bodes well for the CEO’s plans in the area. Musk, after all, has previously butted heads with officials, resulting in his two biggest ventures, electric vehicle maker Tesla and private space company SpaceX, officially relocating their headquarters to Texas.

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