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SpaceX beats Falcon 9 recovery records after company’s heaviest launch ever

Falcon 9 B1049.3 returned to port on May 28th after launching ~18.5 tons (~40,000 lb) into orbit, SpaceX's heaviest payload ever. (Tom Cross)

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Completed on May 30th, SpaceX’s latest Falcon 9 booster recovery smashed several internal speed records, unofficially cataloged over the years by watchful fans.

In short, as the company’s experienced recovery technicians continue to gain experience and grow familiar with Falcon 9 Block 5, the length of booster recoveries have consistently decreased in the 12 months since Block 5’s launch debut. Already, the efficiency of recovery processing has gotten to the point that – once SpaceX optimizes Block 5’s design for refurbishment-free reuse – there should be no logistical reason the company can’t fly the same booster twice in ~24-48 hours.

https://twitter.com/_TomCross_/status/1133438786841600002

The road to rapid reusability

Rarely will it make headlines, but the fact remains that SpaceX’s ultimate goal is not just to reuse Falcon 9 (and other) boosters, but to do so with a level of routine efficiency approaching that of modern passenger aircraft. It’s reasonable to assume that chemical rockets might never reach those capabilities, but they may certainly be able to improve enough to radically change the relationship between humans and spaceflight.

Along that line of thinking, SpaceX CEO Elon Musk decided years ago that an excellent representative goal for Falcon 9 would be to launch the same booster twice in 24 hours. In the last year or so, that largely arbitrary target has changed a bit and is now believed to be a bit wider, aiming for booster reuse within a few days of recovery. This is a pragmatic adjustment more than a technical criticism of Falcon 9.

In general, Falcon 9 simply doesn’t have the performance necessary for routine reusability timelines measured in hours. The majority of SpaceX launches need enough of Falcon 9’s performance to necessitate recovery aboard one of SpaceX’s two drone ships, typically stationed at least a 200-300 km (100-200 mi) offshore. That fact alone almost single-handedly kills any chance of sub-24-hour booster reuse, given that the process of towing the booster-carrying drone ship back to port happens at a max speed of ~10 mph (15 km/h). Just gaining permission to enter the port itself often involves waits of 6+ hours a few miles offshore.

Low orbit, low mass Falcon 9 missions are much more promising for extremely rapid reusability, given that both of SpaceX’s West and East coast landing zones are located just a few miles (or less than 1500 feet, in the case of LZ-4) from their corresponding launch pads and processing facilities. However, these missions are quite rare, while SpaceX’s own low Earth orbit (LEO) Starlink launches will likely involve payloads so heavy that long-distance drone ship recoveries will be necessary.

Falcon 9 B1049 returns to port after its third successful launch and landing in eight months. (Tom Cross)

Finally, there are Falcon Heavy launches, most of which will allow for both side boosters to return to the Florida coast for landings at LZ-1/LZ-2. However, these pose their own barriers to rapid reuse, mainly due to the fact that side boosters – while technically just Falcon 9 boosters – would need major changes to support a single-stack Falcon 9 launch. Falcon Heavy launches simply aren’t going to happen back-to-back over a period of 24-48 hours, so that option is also out of the question.

This means that SpaceX’s only real option for practical rapid reuse is to instead focus on something closer to a weekly launch capability for Block 5 boosters, meaning that the same booster would be able to launch, land, return to shore, and prepare for the next launch in the same week. Even then, launch site readiness may still stand in the way of truly radical improvements in booster reuse and launch frequency. After each launch, SpaceX’s pads and transporter/erectors take a significant beating, requiring routine repairs and maintenance before returning to flight-readiness. Barring major improvements, SpaceX has demonstrated minimum launch-to-launch times of roughly 10 days, and cutting that figure by 50-90% will be a major challenge for a rocket as powerful as Falcon 9.

B1049 takes a step forward

Despite the many logistical reasons that Falcon 9 will likely never lend itself to routine ~24-hour reusability, having that latent capability would still mean that the hardware is advanced enough to offer that efficiency. Even if SpaceX can’t literally fly each booster at its operational capacity, nearly refurbishment-free reflights will still translate into dramatically lower launch costs. Modern civilian aircraft need not fly every second of every day to still be affordable to operate (excluding amortization costs).

Ultimately, SpaceX has been taking small steps in that direction ever since the company began recovering (and reusing) Falcon 9 boosters. Falcon 9 B1049’s third recovery has been one of the best (and most record-breaking) steps yet, but those records were only just broken The most significant statistic to come out of the post-Starlink v0.9 recovery is that B1049.3 took less than 30 hours to go from docking in port to being horizontal on a SpaceX booster transporter. The previous record-holder was Falcon 9 B1046.2, requiring approximately 40 hours for the same feat. B1049.3 also holds the record for fastest recovery overall – just 48 hours from docking to being transported to a SpaceX hangar – but only beat B1051 by about half an hour. In general, Falcon 9 Block 5 has been privy to consistently quick recovery operations and B1049 is just the latest in a long line of reusable SpaceX rockets.

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Falcon 9 B1049.3 returned to Port Canaveral on May 28th. (Tom Cross)
B1049.3 bares its well-worn Merlin 1D engines and engine section. (Tom Cross)
(Tom Cross)

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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 Cybercab spotted with interesting charging solution, stimulating discussion

The port is located in the rear of the vehicle and features a manual door and latch for plug-in, and the video shows an employee connecting to a Tesla Supercharger.

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Credit: What's Inside | X

Tesla Cybercab units are being tested publicly on roads throughout various areas of the United States, and a recent sighting of the vehicle’s charging port has certainly stimulated some discussions throughout the community.

The Cybercab is geared toward being a fully-autonomous vehicle, void of a steering wheel or pedals, only operating with the use of the Full Self-Driving suite. Everything from the driving itself to the charging to the cleaning is intended to be operated autonomously.

But a recent sighting of the vehicle has incited some speculation as to whether the vehicle might have some manual features, which would make sense, but let’s take a look:

The port is located in the rear of the vehicle and features a manual door and latch for plug-in, and the video shows an employee connecting to a Tesla Supercharger.

Now, it is important to remember these are prototype vehicles, and not the final product. Additionally, Tesla has said it plans to introduce wireless induction charging in the future, but it is not currently available, so these units need to have some ability to charge.

However, there are some arguments for a charging system like this, especially as the operation of the Cybercab begins after production starts, which is scheduled for April.

Wireless for Operation, Wired for Downtime

It seems ideal to use induction charging when the Cybercab is in operation. As it is for most Tesla owners taking roadtrips, Supercharging stops are only a few minutes long for the most part.

The Cybercab would benefit from more frequent Supercharging stops in between rides while it is operating a ride-sharing program.

Tesla wireless charging patent revealed ahead of Robotaxi unveiling event

However, when the vehicle rolls back to its hub for cleaning and maintenance, standard charging, where it is plugged into a charger of some kind, seems more ideal.

In the 45-minutes that the car is being cleaned and is having maintenance, it could be fully charged and ready for another full shift of rides, grabbing a few miles of range with induction charging when it’s out and about.

Induction Charging Challenges

Induction charging is still something that presents many challenges for companies that use it for anything, including things as trivial as charging cell phones.

While it is convenient, a lot of the charge is lost during heat transfer, which is something that is common with wireless charging solutions. Even in Teslas, the wireless charging mat present in its vehicles has been a common complaint among owners, so much so that the company recently included a feature to turn them off.

Production Timing and Potential Challenges

With Tesla planning to begin Cybercab production in April, the real challenge with the induction charging is whether the company can develop an effective wireless apparatus in that short time frame.

It has been in development for several years, but solving the issue with heat and energy loss is something that is not an easy task.

In the short-term, Tesla could utilize this port for normal Supercharging operation on the Cybercab. Eventually, it could be phased out as induction charging proves to be a more effective and convenient option.

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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.

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tesla 4680
Image used with permission for Teslarati. (Credit: Tom Cross)

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.”

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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.

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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.

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Credit: Tesla/YouTube

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. 

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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. 

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