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SpaceX recovers fairing intact for the first time, Starlink communicating back to Earth

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9 years ago

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With the launch of PAZ and two of their own Starlink demo satellites, SpaceX has completed its fourth successful launch of 2018, and continued an aggressive series of reusability-focused flight-tests.

Amazingly, the company managed to successfully recover a fairing intact for the first time ever, an absolutely crucial step towards ramping the Falcon family’s launch cadence and reusability. According to CEO Elon Musk, SpaceX’s fairing recovery vessel Mr. Steven missed the fairing by a few hundred meters, meaning that the fairing gently landed in the Pacific Ocean, rather than Mr. Steven’s now-famous fairing recovery net. This is quite possibly the first time in aerospace history that an orbital rocket’s payload fairing has been recovered intact, and the fairing in question looks very much intact.

As mentioned by Musk, that massive piece of hardware had to survive reentry into Earth’s atmosphere at no less than Mach 8, considerably more than two times faster than the famous SR-71 Blackbird spy plane. While the fairing’s parafoil appears to have sunk after being quickly detached, careful observers will note three vertical bars at its three corners, almost certainly the points where that parafoil attaches to them and allows it to gently float down to the ocean surface.  While not nearly as consequential as SpaceX’s growing expertise with Falcon booster recovery and reuse, each fairing – made largely of carbon fiber composites – takes a huge amount of time and effort to complete, and cost upwards of $3 million each ($6m for both halves). In this sense, SpaceX has managed to recover a pallet of cash, as Musk humorously likened the effort fairing reuse to in 2017.

Given just how good the fairing’s condition appears to be, as well as the calm sea states, it’s very likely that SpaceX will try to pick up the landed fairing with a crane, although that would require a different vessel – Mr. Steven has no crane! Teslarati’s Pauline Acalin will undoubtedly be checking out the Port of San Pedro once Mr. Steven has returned to shore, in hopes of capturing the first-ever photos of a recovered orbital rocket fairing.

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Falcon 9 roars into the dark California sky with PAZ and Starlink. (Pauline Acalin)

Starlink hopes tempered despite apparent success

While only mentioned a few times during the webcast, the Falcon 9 that launched earlier today was also carrying additional co-passengers – two SpaceX demonstration satellites, in this case. Confirmed to have successfully deployed and begun communicating with SpaceX ground control, this is another huge accomplishment for SpaceX and marks their first-ever steps into dedicated satellite manufacturing and operation. Despite the significance of this event, SpaceX was keen to lower expectations for the satellite internet network, named Starlink. The following statement was provided during the webcast:

“Even if these satellites work as planned, we still have considerable technical work ahead of us to design and deploy a low Earth orbit satellite constellation. If successful, [this system] would provide people in low to moderate population densities around the world with affordable, high-speed internet access, including many that have never had internet access before.”

https://www.instagram.com/p/BfgTyTzgYVm/

For all intents and purposes, this appears to be a significant departure from previous statements given about Starlink by the rocket company. The explicit mention of “low and moderate” population densities being the only focus of service contrasts heavily with a general sense that Starlink was intended from the outset to provide universal internet around the globe to anyone who could afford the service. This certainly serves as a confirmation that there are major technological hurdles that will need to be overcome for Starlink to become the universal internet many have come to hope for from SpaceX – it would appear that it will be quite difficult to serve high-density populations with SpaceX’s current choice of technologies for their constellation.

Still, the demand is undeniably there. Even readers of Teslarati expressed an immediate desire to ditch their cable companies and ISPs, both in the US and abroad. If SpaceX can make it happen, they will have hordes of eager ISP-hating internet users desperate for any alternatives, and your author is proudly among them. The badly served aside, it sounds like SpaceX may be pivoting towards Starlink as a method of connecting the underserved – mainly those in rural or undeveloped areas. Even in the US, this is a major problem for those that do not live near large cities, and US ISPs are exceptionally anti-consumer in these situations – often times charging obscene costs for cable installation or outright refusing to provide coverage. Starlink could be a boon for those individuals in the US and elsewhere, especially where a simple lack of infrastructure is the cause. Much of Africa suffers from this, although mobile networks have become a backbone for a relatively unique pattern of mobile phone usage.

Here’s to hoping that SpaceX manages to once again rise to an exceptional technological challenge. As with all R&D efforts, the company’s satellite effort would be helped immensely with additional funds, and thankfully Falcon 9 Block 5 is very nearly ready to fly its first missions. This highly reusable iteration of the rocket could enable SpaceX to fly dozens of missions with a single Falcon 9 booster, and would thus enable unprecedented profit margins for a launch company, at least in the interim. Eventually, SpaceX is bound to bring down its prices for the customer, but the first need to recoup their reusability and Falcon Heavy investments, while also ensuring a sound business plan to support the development of their BFR and BFS vehicles that may one day enable the colonization of space. Starlink may be another beneficiary of those profits, and could itself one day act as a source of reliable funding for SpaceX’s interplanetary endeavors.

Teslarati   –   Instagram – Twitter

Tom Cross – Twitter

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Pauline Acalin – Twitter

Eric Ralph – Twitter

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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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3 hours ago

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September 18, 2026

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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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22 hours ago

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September 18, 2026

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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.

Published

2 days ago

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September 17, 2026

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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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