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SpaceX prepares for last launch until August: Caution over cadence

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After a second automatic T-10s launch abort Monday night, Elon Musk expressed a welcome prioritization of caution over an attempt to break cadence records. As such, the launch team at LC-39A are standing down an attempt today and instead conducting a full review of the Falcon 9 vehicle and ground systems, pushing the launch to either July 5th or 6th. As Musk transparently phrased it, there is only one chance to get a rocket launch right.

Following a truly unprecedented series of launches for the company, there was understandably a bit of annoyance from fans watching the coverage for a second time, as well as from journalists seeking to cover the launch. I think a tweet from former NASA Space Shuttle Program Manager Wayne Hale summed up the proper response most coherently, however, stating that “it’s tough to remain vigilant and do the right thing, extremely tough after a couple of launch scrubs and [with] range closure looming”. Remaining vigilant is precisely what SpaceX is doing by calling off another attempt on July 4th and choosing to instead carefully examine the systems involved to ensure that there is no real issue with pad or vehicle hardware.

For launch companies, there are an untold number of external and internal pressures urging executives to attempt launches, be those financial, political, or something as simple as employees wanting to get home for a holiday. However, past failures of launch vehicles, particularly the Space Shuttle, have demonstrated that constant vigilance is a necessity when dealing with rocketry. Wayne Hale was flight director for forty Shuttle launches. In fact, he became Program Manager the day of the Columbia disaster, which occurred at the beginning of February in 2003.

In this context, his statement is almost certainly intended as positive – albeit solemn – encouragement for the choice to take a more cautious route before attempting another launch. SpaceX itself has experienced two widely publicized failures of the Falcon 9, with the most recent of those having occurred less than ten months ago. After China suffered a complex failure during the second launch of their Long March 5 heavy lift vehicle last Sunday, Musk offered sympathy for those involved. Any failure in the launch industry often acts as a wake-up call for other companies and agencies involved, and undoubtedly becomes a reminder that one cannot become too comfortable or allow launch processes or vehicle manufacturing to become too routine when the stakes are as high as they can be.

It goes without saying that SpaceX is sharply aware of the need to ensure reliability and safety as they march ever closer to the debut flight of Crew Dragon and its first crewed launches, likely to occur in early 2018. If the stakes for launching the payloads of commercial customers are already high, the price of failures that could lead to loss of life are unspeakable and ought to humble those fans and bystanders who may be losing patience while waiting for a third (admittedly enthralling) launch. Those eager to watch SpaceX’s live coverage must seek to remember that the launches we love to watch occur because paying customers have placed trust in SpaceX to deliver their payloads to orbit, be those payloads massive geostationary communications satellites or astronauts and cargo headed to the ISS. Rightfully so, the customer will always come first, and routine live coverage of rocket launches must always be treated as the luxury it is for the indefinite future.

SpaceX has successfully recovery and reused both Falcon 9 and Cargo Dragon in the last several weeks, and has also recovered three first stages from the three related launches that occurred in that same time period. (SpaceX)

Admittedly, a cornerstone of SpaceX’s mission as a company is making access to orbit reliable, affordable, and routine, but there will always be risk in rocket launches, just as there will always be risk when one boards a plane, drives a car, or simply walks down the sidewalk along a busy street. Minimizing and reducing the risk present in spaceflight will take a considerable amount of time and effort, and doing what is necessary to prevent failures from negatively impacting the customers that make SpaceX viable as a company is both a rational and ethical strategy.

Returning to current events, the Falcon 9 intended to launch Intelsat 35e went horizontal on July 4, and is likely now in the integration facility present at LC-39A, providing easier access to engineers as they comb over the vehicle to ensure its health. After an absolutely picturesque launch attempt Monday evening, weather is looking even better for a potential launch attempt on either Wednesday or Thursday evening.

If the vehicle and pad cooperate, Intelsat 35e will be a facing send off for the Eastern Range before it shuts down for the remainder of July to undergo routine maintenance. SpaceX currently does not have Vandenberg (West coast) missions scheduled until August, so July will likely see no launches from the company. There is still plenty to be done in lieu of launching customer payloads, however. LC-40, the pad damaged in the Amos-6 static fire incident last September, is currently preparing to be reactivated, with a recent interview of Gwynne Shotwell pointing to its initial availability sometime in August. Once it is reactivated, all single core Falcon launches will be transferred to LC-40, and LC-39A will begin undergoing structural modifications to accommodate both crewed missions in 2018 and Falcon Heavy, which could debut as early as Q4 of 2017.

The two most visible changes that will occur at LC-39A will be the installation of additional hold-down clamps and modifications to the Transporter Erector, as well as a Crew Access Arm, which will be attached to the large, vertical structure seen directly right of Falcon 9. Of note, it is very likely that at least two, if not all three of the first Falcon Heavy’s cores are already present at the Cape. After years of being deemed a paper rocket, Falcon Heavy is indeed very real and very close to being able to conduct its first launches.

A month of no launches from SpaceX will undoubtedly be less than thrilling, but the Air Force and Kennedy Space Center employees will get a much-deserved break from a busy launch manifest ahead of what will likely be an even busier final four months of the year. There is a lot to look forward to.

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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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Musk’s massive Terafab project will get final location soon

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Credit: SpaceX

Elon Musk’s massive Terafab project, which will be the first true conglomeration between each of his major entities, is set to get its final location soon, the CEO said on Tesla’s recent earnings call.

“The Terafab, we expect to announce a location soon, and provide more details about our plans in that regard. We’ll leave that to the product, the launch announcement rather than try to squeeze it into an earnings call,” Musk said last Wednesday.

Tesla Terafab set for launch: Inside the $20B AI chip factory that will reshape the auto industry

Terafab was announced by Musk back in March and was essentially a massive, vertically integrated semiconductor manufacturing project that would provide all the chips the three companies needed for their AI initiatives without needing third-party companies.

The plant will produce over 1 terawatt of AI compute each year, and will help back up projects like Optimus, Full Self-Driving, and other AI-based projects that Musk’s companies are working on.

In April, less than a month after the project was launched, Intel announced it would join the project, contributing manufacturing expertise and consulting to Terafab as a whole. Intel is one of three chip manufacturers that produce sub-5 nanometer chips at scale. TSMC and Samsung are the other two.

However, there was no true indication of where Terafab would end up, but most believe it will likely be somewhere in Texas. Business Insider has reported that SpaceX plans to build out Terafab in Grimes County, Texas, but this is unconfirmed.

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Musk confirmed recently that it would not be on Giga Texas property, as it is simply too large.

Terafab holds much of Musk’s grand ambitions for the future within its construct. It holds so much responsibility for the future and the biggest projects that Musk’s companies can imagine.

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“I think this is a very big announcement and it deserves to have its own day in the spotlight and not be squeezed into an earnings call,” he said. “I do think Terafab is going to be an amazing initiative and a necessary one, and one without which we will be constrained in our ability to scale Optimus production, because we simply won’t have enough AI chips.”

He continued by stating that Terafab is necessary for scaling Optimus, which Musk said could be the biggest product of any kind of all time. “It’s crucial to solve that, and we’ll have to solve memory, logic, and packaging in order to scale Optimus.”

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Elon Musk reveals SpaceX performed secret Starship test on Flight 13

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Credit: SpaceX

SpaceX performed a secret test on a specific portion of Starship with its recent 13th test flight last week, CEO Elon Musk revealed.

Starship’s 13th test flight took place last Friday, and in many aspects, it was one of the most overwhelmingly successful launches in the project’s history.

All of the mission objectives were met without incident, both the Super Heavy Booster and Ship managed to perform safe splashdowns in the Gulf of America and the Indian Ocean, respectively, and the deployment of Starlink satellites came and went without any complications.

However, there was more on the agenda for SpaceX with Flight 13. Musk revealed an internal test of the ship’s heat shield tiles, as the space exploration company wanted to push them to the limits after previous issues.

Many noticed that Starship’s initial launch seemed to be more accelerated than normal, and that was not a mistake. Musk revealed that SpaceX decided to give Flight 13 an intentionally aggressive acceleration rate in an effort to test how well the tiles would remain attached to the ship:

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SpaceX had issues with some of the heat shield tiles remaining attached early on in the Starship program. The first six test flights presented some kind of anomaly with them, so the company’s big focus with them was to figure out a way to keep them intact through the duration of the flight.

Things truly improved as Flight 10 showed that ceramic tiles generally stayed attached to the ship far better due to refined attachment, as SpaceX utilized pins instead of adhesives. Flights 10 through 13 truly showed some clear progress with the heat shield tiles, and this latest test seems to be where some real progress was noticed, especially by Musk.

The 13th Starship launch last Friday was the second with Starship V3, SpaceX’s latest and greatest iteration of the spacecraft. Goals and ambitions are getting even grander as the project continues to progress. Musk has already hinted that SpaceX will likely try to catch Starship with Flight 14.

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SpaceX wants to catch Starship for launch 14, Elon Musk says

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Credit: SpaceX

Just hours after Starship Flight 13 achieved a successful soft splashdown of its upper stage in the Indian Ocean on July 24, Elon Musk announced an ambitious next step for the company’s next launch of the rocket.

“Unless we discover problems after mission data review, SpaceX will attempt to catch the ship with the tower on [the] next flight,” the SpaceX CEO posted on X on Friday.

That “next flight” is expected to be Flight 14. The plan involves returning the Starship upper stage, commonly called the “ship,” to the Starbase launch tower in Texas and catching it mid-air using the same mechanical “chopsticks” arms that have already proven themselves with the Super Heavy booster.

A successful catch would mark the first time an orbital-class upper stage has been recovered this way, advancing SpaceX’s goal of full and rapid reusability for the entire vehicle.

SpaceX has already demonstrated the tower-catch technique multiple times with Super Heavy. The first successful catch came on Flight 5 in October 2024, when Booster 12 was plucked from the sky by the Mechazilla arms. Subsequent flights, including those involving Boosters 14 and 15, repeated the feat. Several of those recovered boosters were later inspected, refurbished, and flown again, proving the system’s viability for quick turnaround.

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Traditional reusable rockets, such as SpaceX’s own Falcon 9 or Blue Origin’s New Shepard, land on legs either on land or droneships. Rocket Lab has recovered its small Electron first stages by helicopter, but those are far lighter vehicles.

SpaceX Starship just nailed something it’s never done before

The China Academy of Launch Vehicle Technology (CALT), a subsidiary of the China Aerospace Science and Technology Corp. (CASC), completed a catch of its booster on July 10. They are the only entity besides SpaceX to attempt and complete the feat.

Flight 13 provided encouraging data. The ship executed a controlled reentry, flipped, and soft-landed intact in the ocean after deploying Starlink satellites, offering the first clear post-splashdown views of an undamaged heat shield. The Super Heavy booster, meanwhile, experienced a harder splashdown in the Gulf of America.

Musk has previously stressed that ship catches would only follow multiple successful soft ocean landings to minimize risk of debris over land.

If Flight 14 succeeds, SpaceX would take a major stride toward routine, rapid reuse of both stages—critical for lowering launch costs and supporting ambitious plans for lunar and Mars missions. For now, teams are reviewing the Flight 13 data. Should everything check out, the next Starship flight could deliver one of the most spectacular recoveries in aerospace history.

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