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SpaceX competitor ULA CEO still questions the economic value of reusable rockets

Falcon Heavy Block 5 side boosters B1052 and B1053 are set to duplicate this spectacular simultaneous landing as part of their second launch. (Credit: SpaceX)

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SpaceX has made a name for itself for being one of the only private space companies today to deploy a fleet of rockets that are capable of being reused for multiple missions. Elon Musk has sworn by the economics of rocket reusability, and this is shown by SpaceX’s launch prices compared to competitors that use expendable rockets. Yet for Tory Bruno, the CEO of ULA, the economic sense behind reusable rockets like the Falcon 9 is still questionable. 

Interestingly enough, the ULA is poised to use Blue Origin’s BE-4 engines for the first stage of its expendable Vulcan rocket. Like SpaceX, Blue Origin’s vision of spaceflight involves rockets that can be reused multiple times before they are retired. ULA, for its part, notes that it may decide to recover and reuse the Vulcan’s BE-4 engines down the road, using a system that disengages the units after launch and having them fall back through the atmosphere while being protected by an inflatable hypersonic shield. 

A helicopter would then be positioned to catch the engine section midair while it makes its descent. ULA has come up with a noteworthy name for this system: the Sensible Modular Autonomous Return Technology, or SMART approach. In a statement to Aviation Week, ULA CEO Tory Bruno explained the strategy behind the company’s SMART strategy. 

SpaceX CEO Elon Musk says Falcon 9’s latest booster landing – pictured here – “expanded [the envelope]” for all future rocket recovery efforts. (Credit: SpaceX)

“It does not impact, in any significant way, the overall performance of the launch vehicle because you don’t have to save fuel to fly home with. You still get to burn up all your fuel, separate your engine, which is the most expensive piece, and recover it,” Bruno said. 

Elaborating further, the ULA CEO mentioned that ultimately, he believes that the economics of reusable rockets is still up for question. Bruno argued that it is still difficult to ensure that using reusable rockets instead of expendable machines actually saves money. 

“We have not really changed our assessment over the last couple of years because we have yet to see the other forms of reusability—flyback or propulsive return to Earth—demonstrate economic sustainability on a recurring basis. It’s pretty darn hard to make that actually save money… We’ve seen nothing yet that changes our analysis on that,” the ULA CEO said. 

The ULA CEO’s points about the possible lack of savings on reusable rockets put him in stark contrast with other noteworthy leaders in the space industry. Apart from SpaceX CEO Elon Musk, fellow billionaire Jeff Bezos of Blue Origin is also intently focused on using reusable rockets. Even Rocket Lab CEO Peter Beck, whose company designs and launches small rockets, has embraced the idea of reusing previously-flown boosters

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(Credit: Rocket Lab)

In a statement in August 2019, for example, Beck noted that he actually had to “eat his hat” when it came to reusing his company’s rockets. “For a long time, I said we weren’t going to do reusability. This is one of those occasions where I have to eat my hat,” the Rocket Lab CEO said. 

That being said, the fact that the ULA CEO is considering reusing the Vulcan’s BE-4 engines may be considered as a small win for reusable rockets. Perhaps in the near future, Bruno would see exactly why SpaceX has grown so much over the years, and why the company is practically launching its Starlink satellite internet system at a minimal cost. 

“We view (rocket reuse) as sort of a journey. We’re going to start with the engines because we’re pretty sure we can save money with that and pass those savings on right away. As we learn more by doing, we’ll continue to assess other valuable parts of the rocket, and we may discover that we can do that there as well. 

“There is one funny thing about reusability. As you make your rocket less expensive, and you make parts of your rocket less expensive, it’s harder to close a business case on reuse because the thing you’re recovering isn’t as valuable. There’s a balance there,” Bruno said. 

Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Tesla Optimus Gen 3 shows off a cleaner, factory-ready design in new app discovery

Renders hidden inside Tesla’s Android app show Optimus Gen 3’s design before any official reveal.

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla may have accidentally given a first look at its newest Optimus Gen 3 humanoid robot when photos were found in the Tesla smartphone app.

Design files tucked inside a recent Android version of the Tesla app appear to show the third generation humanoid robot next to the older Gen 2.5 prototype. The assets were extracted from the app package by Tesla community member @wholemars, who posted the renders on X late Tuesday night before deleting them. The Tesla Newswire reshared the side by side comparison on Wednesday, and the images have circulated widely since.

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

The files are labeled “gen3” and were built as models for Tesla app’s own interface, as validated directly by Grok to be official.

The comparison shows a robot that looks built for a factory line rather than a lab bench. Gen 2.5’s exposed mechanical linkages and gold plating on the knees and shins are gone. In their place, Gen 3 uses matte black fairings on the lower legs, paired with a more contoured champagne gold body. Flexible covers now seal the joint where the torso meets the upper thighs, keeping bearings and moving parts sealed from debris and unnecessary contact.

The body panels fit more tightly, and the hands, which Tesla has said carry 22 degrees of freedom, look far more refined than those on earlier units.

This most recent leak fills a gap Tesla has left open for most of the year. Elon Musk said on March 31 that Optimus 3 was walking around but needed “some finishing touches” before it could be shown, a delay Teslarati covered when Tesla missed its first quarter reveal target. Musk later said Tesla would hold the design back until closer to production, partly to keep competitors from copying it. No reveal date has been announced.

The app itself has been preparing for Optimus for months. In July, code in the Tesla app pointed to a dedicated robot phone key, a consent screen for collecting video and spatial data while Optimus works inside a home, and an alert system for low battery and mechanical faults. Finished 3D models of Gen 3 suggest the interface owners will eventually use is moving past placeholder code toward something Tesla intends to ship.

Manufacturing is moving in parallel. Tesla tore out the original Model S and Model X lines at Fremont this summer to make room for Optimus production, with a planned capacity of one million robots a year. At Giga Texas, the steel frame of a dedicated Optimus factory is nearing completion ahead of a targeted 2027 start, with Musk pointing to an eventual output of 10 million units annually.

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Tesla Semi lands the biggest electric truck deal in U.S. history

Tesla leads a record 2,500 truck order, but not every truck will be a Semi.

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Tesla has landed the largest electric truck order in U.S. history. ZET SCALE, a new alliance of shippers and carriers, named Tesla its primary manufacturer on Tuesday for an initial order of 2,500 electric Class 8 trucks. The deal alone would nearly double the number of electric heavy trucks operating in the country.

According to the press release from Catalyst Mobility, the nonprofit formerly known as CALSTART, Kenworth, RIDE and Volvo were also selected as secondary manufacturers that carriers can pick if their operations call for it. No split between the four brands has been published, so the exact number of Semis in the order is not yet known.

Tesla won the top slot through a competitive request for proposals. The alliance, which Catalyst Mobility runs with the Smart Freight Centre, scored bidders on price, range, charging capability and production capacity. Pooling freight demand from founding shippers, including Microsoft and PepsiCo, let every truck maker bid lower than it would for a single fleet. “The Tesla Semi is designed for lower cost per mile operations than diesel,” said Dan Priestley, director of the Tesla Semi program, as noted in the press release.

The financing is built to pull in carriers who have avoided electric trucks. ZET Financial is issuing the purchase order for all 2,500 units and will place them with fleets through a fair market value lease. The trucks will be deployed over the next few years across 10 freight hubs in Los Angeles, Stockton, Bakersfield, Seattle and Tacoma, Houston, Dallas, San Antonio, Chicago, Atlanta, and the Newark and New York area. ZET SCALE says the first order is only the opening round, with a longer term goal of 10,000 trucks or more.

Even if Tesla ends up with only a majority share, it would still be the biggest Semi deal to date. Einride’s 500 unit order in August was the previous record, and WattEV’s 370 truck order in May was the largest California deal at the time. Einride’s CEO has since said he expects all 500 trucks delivered by the end of 2027.

The announcement lands two days before Tesla formally inaugurates its Semi factory in Nevada on September 24. The 1.7 million square foot plant sits next to Gigafactory Nevada’s 4680 cell lines and is designed for 50,000 trucks a year.

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Tesla integrates Grok Bot into its vehicles for the ultimate personal assistant

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Credit: Grok

Tesla has expanded Grok from an in-car chatbot into a hands-free work assistant. On September 22, Tesla officially launched Grok Bot capability, confirming that drivers can now manage email, calendars, files, chats, and tasks by voice and then hand more ambitious errands to the AI-fueled productivity cheat code.

Grok itself is built by xAI. The new car features split into two layers: Connectors link Grok to outside accounts. Grok Bot, currently limited to SuperGrok Heavy subscribers, can complete multi-step tasks such as placing a usual coffee order, booking a reservation, or scheduling an appointment. It truly puts the driver in a nearly complete hands-free driving and productivity setting, with ironically the only task truly requiring your hands being to touch the “Start Self-Driving” button.

We were granted access to Grok Bot’s Tesla integration a few weeks back, and we’ve been able to do a handful of things with it. On a handful of occasions, we’ve used it to order food and have it ready for pickup slightly later into the evening; we’ve managed to pick up groceries after a day of errands with Grok Bot, and outside of the car, it’s helped with budgeting and even my fantasy football draft.

Tesla shows another way to utilize it: in their demo, a driver says “Hey Grok,” asks the assistant to check an inbox, and hears that a message concerns a weekend reservation. Grok then scans the calendar, reports no conflicts, and confirms the Tahoe trip is clear. It can also add check-in details to a road-trip itinerary. The point is not novelty chat. It is keeping eyes on the road, or on Full Self-Driving, while the car handles the paperwork of a trip:

This Grok rollout is not a gadget add-on as much as it is Tesla’s thesis in software form: the car should stop being a machine you operate and start being a room you occupy.

Connectors and Grok Bot treat the cabin as an office that happens to move, and that has truly been Tesla’s intention for years now. The car has slowly become an extension of a home more than a vehicle. Inbox, calendar, groceries, takeout, and reservations become voice work, not dashboard chores that you need to do before you get in your car.

Responsibility shifts from the driver to the stack, and as many Tesla owners rely on FSD for travel, Grok Bot now handles the monotony of dinner reservations or appointments.

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