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SpaceX hot-fires Crew Dragon’s Falcon 9 as separate rocket spied in Arizona

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A SpaceX Falcon 9 booster has been spotted traveling eastbound through Wilcox, AZ, indicating a shipment from the company’s Hawthorne, CA rocket factory to its McGregor, TX facilities for hot-fire acceptance testing.

Captured by Reddit user codercotton on October 28th, this first stage (S1) is headed to Texas at the same time as SpaceX’s facilities appear to be wrapping up an extended test campaign with the Falcon 9 rocket stages that will launch an uncrewed Crew Dragon on the upgraded spacecraft’s first trip into orbit.

This duo of Falcon 9 appearances highlights an unusual few months of what is often called “core spotting” by close followers of SpaceX. Typically, SpaceX ships and hot-fire tests a Falcon 9 booster every month, give or take roughly two weeks. It’s clear, however, that the imminent start of Crew Dragon launches under NASA’s Commercial Crew Program (CCP) has created some unique requirements with respect to both booster, upper stage, and individual engine testing in Texas.

For example, Falcon 9 B1051 – a new booster assigned to Crew Dragon’s first uncrewed demonstration launch (DM-1) – appears to have been testing in McGregor for the better part of three months, apparently including multiple hot-fire tests of the rocket. Prior to Commercial Crew, a  nominal round of acceptance testing in McGregor would be expected to last between two and four weeks between arrival and departure. As such, spending three months or more in McGregor is very unusual, particularly for a brand-new booster like B1051.

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B1051’s extended period of testing can likely be traced back to two main factors. At a more technical level, B1051 could be the first Falcon 9 Block 5 booster to have SpaceX’s upgraded COPVs (carbon-overwrapped pressure vessels) – bottles designed to hold helium and nitrogen at pressures around 5000 psi (35 MPa) – fully integrated on both the first and second stages. Perhaps not a major technical hurdle for SpaceX, this milestone is undoubtedly one of NASA’s most myopic and obsessive mountains-out-of-molehills in terms of the intense ‘certification’ burdens dumped on SpaceX over the course of CCP. SpaceX has apparently spent at least 1.5 years systematically designing, testing to destruction, and redesigning an in-house COPV, to the extent that CEO Elon Musk described the updated design as “by far the most advanced pressure vessel ever developed by humanity … It’s nuts.”

Juggling Falcon 9 tests

Despite the extreme lengths of testing apparently required for the Falcon 9s that will launch Crew Dragon, it can be concluded with some certainty that SpaceX has still managed to fit in normal tests of a number of non-Crew boosters, upper stages, and Merlins. According to the above SpaceX tweet, B1051 is clearly still in Texas and is unlikely to leave for Florida until November (several days are needed to prepare a booster for transport). However, a different booster was spotted heading from California to Texas just this morning.

Further, Falcon 9 booster B1054 – nearly complete and stationed in front of the only real exit route – was spotted in SpaceX’s Hawthorne factory in mid-September, while an unknown first stage was caught departing the factory for Texas roughly two weeks later. Finally, at the same time as the mystery booster was being trucked to Texas, an even more mysterious Falcon 9 – visibly sooty and thus flight-proven – was spotted inside one of SpaceX Hawthorne’s separate refurbishment hangars, with at least three Merlins removed from its octaweb. Perhaps this is somehow related to the Falcon 9 booster (missing four of nine Merlins) headed East on October 28th.

Finally, according to a member of the /r/SpaceX subreddit, a separate Falcon 9 booster apparently arrived at SpaceX’s Vandenberg, CA launch facilities on October 26th, perhaps Falcon 9 B1046.3 preparing to launch for the third time for Spaceflight’s SSO-A rideshare mission, NET November 19.

https://twitter.com/_TomCross_/status/1048483536917823488

As with most things SpaceX, definitive answers are exceedingly rare when it comes to day-to-day operations like Falcon 9 transportation and even official confirmation of the particular boosters involved with any given launch. Understandably, these more esoteric details are probably treated as “need-to-know” only, and while I and many others would love to know, we certainly don’t *need* to know.

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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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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

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Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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Investor's Corner

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

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Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Investor's Corner

Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

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Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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