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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.

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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Elon Musk’s Boring Company lands a new Middle East deal, and Nashville is about to get faster

The Boring Company signs Abu Dhabi tunnel agreement while adding more Prufrock machines in Nashville.

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The Boring Company has signed an agreement with Abu Dhabi to study underground transport and utility tunnels across the emirate, adding a second UAE city to its pipeline as it prepares to also scale up tunneling back home in Nashville.

The deal was signed Thursday at the Liveability and Investment Exhibition (LIVEX 2026) by Boring Company President Steve Davis and Maysarah Mahmoud Salim Eid, director general of the Abu Dhabi Projects and Infrastructure Centre (ADPIC), according to the Abu Dhabi Media Office. Mohamed Ali Al Shorafa, chairman of the emirate’s Department of Municipalities and Transport, attended the signing.

Under the agreement, the two sides will assess feasibility, delivery and operating models for tunnels that could carry passengers or utilities. They will also look at Abu Dhabi’s potential as a regional hub for tunneling work. The current phase is exploratory, and no construction commitment or project budget has been announced.

“Abu Dhabi provides an ideal environment to explore the next generation of underground infrastructure solutions, supported by its ambitious growth vision and strong commitment to advanced technologies,”

Davis said. He added that the company wants to assess how tunnels can “expand urban capacity more efficiently, and enable better use of available space.”

The timing lines up with the money, considering last month, The Boring Company closed a $3 billion Series D led by the UAE and affiliated investors, valuing the company at $23 billion, as Teslarati reported. That round came with a commitment to build more than 150 kilometers of tunnel across the UAE, separate from the Dubai Loop pilot already under contract with Dubai’s Roads and Transport Authority. That pilot covers 6.4 kilometers and four stations linking DIFC and Dubai Mall at a cost of about $154 million.

Back home, The Boring Company projects in Nashville are also scaling up, with the company telling local NewsChannel 5 that a third Prufrock machine could start digging the Music City Loop in late October. A fourth is also targeted before the end of the year. Two machines are already mining Nashville limestone at the same time, and work is underway on a new launch site for the third.

The company said it has made more than 300 design and performance upgrades to its original Nashville machine. It is also working with property owners on more than 40 planned stations, with approvals in place for a future Nashville International Airport connection, a downtown station near the Music City Center, and stops at residential towers and the JW Marriott.

Construction on the Music City Loop began the same evening Tennessee and federal regulators approved the project’s lease in February, and the company targeted its first operational segment for late 2026. Back in Las Vegas, The Boring Company has said it plans to double its Vegas Loop station count by year’s end.

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SpaceX brings four astronauts home after 8 months in space, and the return was flawless

SpaceX Crew Dragon Freedom returned four Crew-12 astronauts home after 237 days aboard the station.

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SpaceX's Crew Dragon Freedom sits aboard the recovery ship Shannon after splashing down off the coast of Los Angeles with the Crew-12 astronauts on October 8, 2026. (Credit: SpaceX)
SpaceX's Crew Dragon Freedom sits aboard the recovery ship Shannon after splashing down off the coast of Los Angeles with the Crew-12 astronauts on October 8, 2026. (Credit: SpaceX)

Four Crew-12 members are back on Earth after 237 days at the International Space Station. SpaceX’s Crew Dragon Freedom splashed down in the Pacific Ocean about 50 miles west of Los Angeles at 11:34 a.m. ET on Thursday.

NASA astronauts Jessica Meir and Jack Hathaway, ESA astronaut Sophie Adenot, and Roscosmos cosmonaut Andrey Fedyaev landed one day after undocking from the station’s Harmony module at 8:05 a.m. ET on Wednesday. NASA confirmed the splashdown minutes later. SpaceX had flagged the 27.5 hour trip home on X while Dragon was still firing its departure burns away from the station.

The descent ran on schedule when Freedom started a nine minute deorbit burn at 10:46 a.m. ET, then hit the thicker atmosphere about 36 minutes later at nearly five miles per second. Chutes deployed at around 18,000 feet, and four main parachutes brought the capsule down to roughly 15 mph at splashdown.

SpaceX fast boats secured Dragon before the recovery ship Shannon hoisted it onto the deck with the crew still inside. Flight surgeons on board ran initial medical checks. All four crew members will be flown ashore by helicopter and then head to NASA’s Johnson Space Center in Houston for rehabilitation.

Crew-12 launched on February 13 from Space Launch Complex 40 at Cape Canaveral, a flight that also marked the first Falcon 9 booster landing at SpaceX’s new LZ-40 pad. Over the mission, the crew completed 3,792 orbits, covered nearly 101 million miles, and carried out four spacewalks to maintain and upgrade the station.

Meir now has 440 cumulative days in space, which places her in NASA’s top 10. This was the first spaceflight for Hathaway and for Adenot, a French Air Force colonel and former helicopter pilot. Fedyaev, who spent 186 days in orbit on Crew-6 in 2023, has now flown two long duration Dragon missions.

The return closes out a busy stretch of Dragon traffic. Crew-13 arrived on October 1 aboard Crew Dragon Grace, which docked just 7 hours and 55 minutes after liftoff, the fastest launch to docking of any U.S. spacecraft in ISS history. Commander Jessica Watkins, pilot Luke Delaney, Canadian Space Agency astronaut Joshua Kutryk, and cosmonaut Sergey Teteryatnikov remain aboard alongside the three person Soyuz MS-29 crew.

With Crew-12 gone, the port is clear for CRS-35, a cargo Dragon carrying the final pair of ISS Roll-Out Solar Arrays. NASA is holding a post-splashdown teleconference at 1:15 p.m. ET covering both the crew’s return and the upcoming cargo launch.

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Elon Musk shuts down talk of TSMC taking over Terafab

Musk says Tesla and SpaceX will build and run Terafab, with TSMC limited to renting.

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SpaceX Terafab rendering

Elon Musk has drawn a firm line around who will be in charge of Terafab, the giant chip factory Tesla and SpaceX are planning in Texas.

Musk replied to a post on X arguing that Taiwan Semiconductor Manufacturing Company (TSMC) would most likely end up owning and operating the plant. “No, we will build and run the fab. Let there be ZERO doubt about that,” Musk wrote. “Maybe TSMC subleases part of the Terafab if they want, but nothing more than that.”

In plain terms, a sublease means TSMC could rent a section of the complex to make chips, similar to a tenant renting one floor of an office tower. The building, the equipment decisions and the daily operation would stay with Tesla and SpaceX.

The comment shuts down speculation that started last week. On October 2, tech journalist Tim Culpan reported that TSMC was exploring ways to help run Terafab’s factories. Musk responded the next day that it was “just discussions, but something may come of it,” as Teslarati reported at the time. That left room for a scenario where the world’s largest contract chipmaker took the wheel. Musk’s latest post closes that door.

Elon Musk teases TSMC as potential Terafab partner

Some background helps explain why this matters. Tesla designs its own AI chips today but pays outside companies like TSMC and Samsung to manufacture them. Musk unveiled Terafab in March as a joint project between Tesla, SpaceX and xAI, arguing that existing suppliers cannot expand fast enough to meet his companies’ future demand. The goal is to produce enough chips each year to supply one terawatt of computing power, roughly 50 times what the entire global AI chip industry produces now.

Those chips are meant for Tesla’s Optimus humanoid robots, the Cybercab and Full Self-Driving computers, along with chips for SpaceX’s planned data centers in orbit. Owning the factory means Musk’s companies would not have to compete with every other chip customer for time on someone else’s production lines.

Intel is still part of the picture. The company signed on in April to help design, build and package chips for the project, and CEO Lip-Bu Tan told Bloomberg this week that Intel will keep working on Terafab despite the TSMC chatter.

The project moved from concept to construction planning over the summer. In August, SpaceX confirmed the Grimes County site about an hour from Houston, sent the county a $10 million payment under its tax abatement deal and said civil work would begin shortly. The first phase carries a $16.8 billion price tag, and total spending across all phases could reach as much as $119 billion.

TSMC chairman C.C. Wei has said a new fab typically takes two to three years to build and another one to two years to reach full output. Tesla and SpaceX have never run one, which is why TSMC’s expertise drew so much attention. Musk’s answer suggests he would rather learn that process in house than hand control of a project this central to Tesla’s robotics and autonomy plans to an outside company.

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