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SpaceX expends Falcon 9 booster for the first time in almost three years

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For the first time since January 2020, SpaceX has intentionally expended a Falcon 9 booster instead of attempting to recover the rocket at sea or on land.

Weighing around 6.6 tons (~14,600 lb) at liftoff, the rare mission sent Intelsat’s twin Maxar-built Galaxy 31 and 32 communications satellites to a high geostationary transfer orbit (GTO) that will allow them to start operating more quickly than a standard GTO would. To launch such a heavy payload to such a high ‘supersynchronous’ transfer orbit, SpaceX – at Intelsat’s request and for a fee – removed all landing-related hardware from Falcon 9 and did not attempt to recover the first stage.

Instead, the rocket put all the propellant that would have otherwise been saved for recovery into its first and only burn, reaching as high a speed as possible before separating from the second stage. Flying for the 14th time since its March 2019 debut, Falcon 9 booster B1051 didn’t perform a controlled flip or attempt to land on a SpaceX drone ship. It’s more likely that the few-dozen-ton rocket – now drained of propellant – reentered Earth’s atmosphere with no control at a speed of roughly 2.7 kilometers per second (~6000 mph), broke apart when it slammed into that atmospheric ‘wall,’ and crashed into the Atlantic Ocean as a cloud of debris.

Having already flown 13 times before its 14th and final mission, it’s safe to say that booster B1051 earned its permanent retirement as an artificial reef. The mission marked the first time a Falcon 9 booster was intentionally discarded since January 2020, when the first Falcon 9 Block 5 booster – B1046 – was destroyed as part of an intentional In-Flight Abort test of SpaceX’s Crew Dragon spacecraft.

Like B1046, B1051 was another fairly new Falcon 9 Block 5 booster. It’s no coincidence that most of the first five or so boosters have been or will be intentionally expended. B1047 was first in August 2019, followed by B1046 five months later, and B1051 in November 2022. B1048 and B1050 both suffered in-flight anomalies that – while they didn’t impact the success of their primary missions – resulted in failed landing attempts. After B1051’s demise, only B1049 remains. Next Spaceflight reports that SpaceX will also intentionally expend that booster after its 11th launch, which will send the Eutelsat 10B communications satellite to a different geostationary transfer orbit as early as this month..

Lacking grid fins and landing legs, Falcon 9 B1047 prepares for its third and final launch. (Spacecom/SpaceX)
B1046’s last flight. (Richard Angle)
B1051 is the third Falcon 9 Block 5 booster to intentionally meet its end. (SpaceX)

While SpaceX likely charged its customers a healthy fee to expend B1049 and B1051, the company is likely not complaining about an opportunity to refine its fleet of Falcon boosters. Though no new variant has been officially introduced, SpaceX has learned more about the design over the years, and newer Falcon Block 5 boosters include improvements that make them easier and cheaper to operate and reuse. It’s also added four new Falcon 9 boosters to the fleet in less than a year, easing the burden created by expending two older but flightworthy boosters weeks apart.

Once B1049 is gone, that fleet will still have one unflown Falcon 9 booster, four unflown Falcon Heavy boosters, ten flown Falcon 9 boosters, and four flown Falcon Heavy side boosters – the latter of which can potentially be converted into Falcon 9 boosters during Falcon Heavy lulls. B1051 was the third Falcon 9 booster to complete 14 launches, meaning that SpaceX has gotten so good at routine reusability that it can safely assume that each new Falcon 9 Falcon Heavy side booster can fulfill the roles of more than a dozen expendable boosters.

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Ultimately, B1051’s sacrifice left Falcon 9’s expendable upper stage with enough performance to boost Galaxy 31 and 32 into a supersynchronous orbit with an apogee more than 58,400 kilometers (~36,300 miles) above Earth’s surface – almost 1.5 times its circumference. Just last month, two recoverable Falcon 9 boosters helped launch a pair of smaller 4.5-ton (~10,000 lb) satellites to almost identical orbits (~57,500 km vs. ~58,400 km). Expending Falcon 9’s booster thus allowed SpaceX to launch almost 50% more payload to a similar supersynchronous GTO, demonstrating the substantial toll booster reuse incurs on launches to higher orbits.

Galaxy 31/32 was SpaceX’s 52nd launch this year and hit a target set by CEO Elon Musk in January. Musk later raised his goal to 60 launches, but SpaceX has managed an average of one Falcon launch every six days for nearly 12 months and has a strong shot at completing another eight launches before the end of the year.

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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Tesla has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

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Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

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The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

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How SpaceX Is raising Raptor’s sea-level thrust while holding engine mass steady

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Credit: SpaceX

SpaceX’s Raptor engine family has steadily increased sea-level thrust while simultaneously reducing mass, turning iterative engineering gains into substantially higher performance for the Super Heavy booster. CEO Elon Musk shed more light on how powerful Raptor 4 will be, and it’s pretty crazy.

Raptor 1 delivered 185 metric tons of thrust at roughly 2,080 kilograms, while Raptor 2 raised that to 230 tons while cutting mass to about 1,630 kilograms. SpaceX data for Raptor 3 lists a target of 280 tons at 1,525 kilograms (with further reductions in associated vehicle hardware), while operational flight ratings have been cited near 250 tons.

This morning, Elon Musk stated that Raptor 4 is expected to reach 300 tons of sea-level thrust at roughly the same mass as Raptor 3. Across these versions, thrust has risen by more than 60 percent from the first engines while engine mass has fallen, producing a sharp improvement in thrust-to-weight ratio. This is a true testament to how great SpaceX engineering has been:

With 33 engines on SuperHeavy, the jump from earlier versions to a 300-ton Raptor 4 would produce roughly 9,900 metric tons of total liftoff thrust, nearly three times the Saturn V’s approximately 3,400 metric tons from its five F-1 engines.

This is not just a larger number on a data sheet, either, as sea-level thrust is the force available the moment the vehicle leaves the pad. This is when it is heaviest and still deep in Earth’s gravity well and dense atmosphere.

Higher levels of sea-level thrust directly improves the initial thrust-to-weight ratio of the full stack. A higher ratio produces faster acceleration off the pad, which shortens the time the rocket has to spend fighting gravity, and gravity losses during the first minute or two of the flight are a major drain on total available delta-v. Every second shaved off of that early climb preserves more propellant energy for reaching orbital velocity or for carrying extra payload.

Because Super Heavy’s engine count is constrained by vehicle diameter and packing density, increasing thrust per engine is the most straightforward way to raise total liftoff performance without redesigning the booster structure or design.

The same-mass target for Raptor 4 is equally important. Holding engine mass roughly constant while raising thrust improves the engine’s own thrust-to-weight ratio and reduces the structural and propellant mass fraction that must be carried solely to support the engines.

Earlier Raptor iterations also simplified or eliminated extensive vehicle-side hardware such as heat shields. These gains compound: more force for less installed mass leaves additional capacity for propellant, payload, or operational margins such as engine-out capability.

For Starship’s architecture, the practical effects are large. Greater liftoff thrust supports heavier vehicles, larger propellant loads, and higher payloads to low Earth orbit, figures SpaceX has targeted in the 100-plus-ton reusable range. That capacity underpins orbital refueling, lunar missions, and eventual Mars cargo and crew flights.

Continued growth in sea-level thrust therefore tightens the gap between theoretical rocket performance and the high flight rates and reusability needed to make large-scale space transport practical.

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Tesla Assisted Driving expands to tenth EU country

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Tesla has expanded its Tesla Assisted Driving (TAD) suite to its tenth European country, as Latvia joined a growing list of European Union member states authorizing the company’s advanced driver assistance technology.

Tesla Europe announced this morning that the system is now approved in Latvia, with a software rollout to begin soon.

The approval and rollout follow recognition of a provisional European type approval originally granted by the Netherlands’ RDW authority on April 10.

Latvia’s Road Traffic Safety Directorate (CSDD) evaluated the Dutch documentation, coordinated with the other national authorities, and reviewed updates from Tesla. These included tightened limits on speed offsets, automatic resets of any manual speed adjustments after each trip, and stronger driver monitoring.

In Europe, the feature is marketed as Tesla Assisted Driving after a recent rule change that labeled the name “Full Self-Driving” as misleading.

Tesla starts showing how FSD will change lives in Europe

The system remains an SAE Level 2 driver assistance tool, not unsupervised autonomy. It can control speed, steering, braking, lane changes, and intersections while following a navigation route. Drivers need not keep their hands on the wheel at all times, yet they must continuously monitor the road and be prepared to intervene immediately.

The sequence of EU recognitions began with the Netherlands in April and continued through Lithuania, Estonia, Denmark, Belgium, Slovenia, Czechia, Croatia, and Slovakia. Most have relied on mutual recognition of the single Dutch provisional approval rather than independent national testing.

These national clearances do not yet constitute bloc-wide authorization. An EU-wide decision requires a qualified majority in the Technical Committee on Motor Vehicles: at least 15 of 27 member states representing 65 percent of the EU population. Larger markets, like Germany, France, and Italy, remain under review, and a vote is expected this December.

However, for Latvian Tesla owners with compatible vehicles and software, the imminent rollout expands access to the supervised system while underscoring that attentive human oversight remains essential.

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