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SpaceX CEO Elon Musk’s hat is safe after ULA Vulcan rocket launch slips to 2023

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In the latest unfortunate development for SpaceX competitor United Launch Alliance’s next-generation Vulcan Centaur rocket, it looks like CEO Elon Musk may have been right all along when he forecast major delays more than three years ago.

In February 2018, even before SpaceX had flown Falcon Heavy for the first time, detractors with axes to grind were already busy attempting to downplay the rocket’s capabilities. On February 6th, Falcon Heavy lifted off for the first time, launching a several-ton Tesla Roadster car into interplanetary space and marking the first debut of a super heavy-lift rocket since the 1980s. That successful launch also meant that ULA’s last bastion of competitive advantage – the Delta IV Heavy rocket, fittingly by way of monopoly – was no longer alone.

Indeed, mere months after its near-flawless debut, Falcon Heavy had already secured its first operational US military launch contract. Delta IV Heavy, on the other hand, had already been preparing for retirement as part of ULA’s plan to replace two complex rockets (Delta and Atlas) with Vulcan.

Musk mercilessly took to task ULA’s heavy-lift rocket when commenters brought it up, noting that Falcon Heavy is largely comparable in a partially-reusable configuration but completely outclasses Delta IV Heavy – while still being dramatically cheaper – if all boosters are expended. The SpaceX CEO estimated that Delta IV Heavy launches would cost ULA significantly more than $400M after the company had effectively announced the end of Delta IV Medium production, though ULA CEO Tory Bruno still claimed a launch price of ~$350M.

In response to a reply noting that ULA’s plan was to replace Atlas V and Delta IV with Vulcan Centaur for launches “after 2020,” Musk pulled no punches, stating that he would “seriously eat [his] hat with a side of mustard if [Vulcan] flies a national security spacecraft before 2023.” At the time, ULA’s CEO did not exactly seem to share Musk’s shocking appraisal of the situation, which was out of left field even for major SpaceX proponents.

At the time, ULA’s party line touted Vulcan Centaur lifting off for the first time in late 2019 – the very next year. Ironically, weeks after Musk threw down his hat-eating gauntlet, ULA announced that Vulcan’s first launch had slipped to “mid-2020” – with a second flight later the same year – to give the company time to move straight to a larger upper stage originally meant to debut later on. Six months later, ULA announced yet another delay for Vulcan, this time pushing the rocket’s launch debut from mid-2020 to no earlier than (NET) April 2021.

Three years later, April 2021 has come and gone and ULA’s latest public Vulcan launch target is now “late 2021,” though that is all but guaranteed to slip into early 2022. In the latest (not-so-) shocking development for ULA’s next-generation rocket, the company has now requested and received permission from the US military to swap out Vulcan for an Atlas V rocket on what would have been the vehicle’s first military launch.

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Exercising a contract loophole that had to have been explicitly designed to give ULA – and ULA alone – the option to fall back on its Atlas V or Delta IV rockets if Vulcan were to experience major delays, Atlas V will now take over the ULA’s USSF-51 mission. As a result, Vulcan Centaur’s first dedicated ‘national security’ launch is now officially scheduled no earlier than 2023, saving Elon Musk from having to eat his hat.

As of May 2021, ULA has now replaced one Vulcan launch with an Atlas V and inexplicably closed nine Atlas V launch contracts with Starlink competitor Amazon, bringing into question whether the company is ever actually going to simplify its rocket production lines. Given that ULA no longer appears to be planning on reusing parts of Vulcan, the only possible way Vulcan will end up more affordable than the rockets its replacing is if it quickly becomes the only rocket ULA produces, which was originally the plan. With ULA now apparently going out of its way to sell Atlas V commercially instead of Vulcan Centaur, it’s difficult to argue that the company has any interest at all in lowering the cost of access to space or offering SpaceX serious competition outside of lobbying and greasing the hinges of revolving doors.

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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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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