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SpaceX restores a Falcon 1 rocket for 10th anniversary of first launch success

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With plans to give the historic rocket its own place on display inside the company’s Hawthorne factory, SpaceX has refurbished the last remaining Falcon 1 rocket booster and an old Merlin 1C engine to create a model representative of the same Falcon 1 that saved SpaceX and made history on September 28th, 2008, becoming the first privately-developed liquid-fuel rocket to reach Earth orbit.

In the process of celebrating the tenth anniversary of that crowning achievement, one is reminded just how meteoric SpaceX’s rise has been over the course of that decade, marked by relentless progress with Falcon 1, Falcon 9, Falcon Heavy, Cargo Dragon, Crew Dragon, and even the early phases of BFR construction.

https://twitter.com/SpaceXJobs/status/1045832573471969281

On that September afternoon ten years ago, SpaceX may well have saved itself from extinction. Running on funding fumes, CEO and founder Elon Musk has long held that the company would have been forced to effectively cease activity and disband after six years of work and three consecutive Falcon 1 failures had drained almost all of the $100 million he had dedicated in 2002.

Reaching orbit is undoubtedly one of the most technologically challenging feats there is and SpaceX’s merciless failures drove that reality home, ranging from a burst propellant line on the first stage Merlin, liquid propellant sloshing problems on the second stage, and overperformance on the first stage engine causing the two stages to impact after separation, among myriad other problems faced outside of actual launch attempts. Thankfully, thanks to the extraordinary group of several hundred early employees that fixed those problems and pushed onwards, Falcon 1’s fourth attempt was almost flawless and successfully placed a boilerplate mass simulator into a roughly circular ~650km orbit.

 

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A bit more than nine months later, SpaceX completed the first and last operational launch of Falcon 1, retired to allow the company to focus fully on Falcon 5 (cancelled a few years later), Falcon 9, and Cargo Dragon. Eleven months after that July 2009 mission, SpaceX successfully launched Falcon 9 for the first time and followed it up with the first launch of a functioning Cargo Dragon spacecraft, which spent several hours testing systems in orbit before reentering Earth’s atmosphere and landing in the Pacific Ocean. Two years later in 2012, SpaceX’s Cargo Dragon became the first commercial spacecraft in history to dock with the International Space Station, with operational NASA Commercial Resupply Services launches beginning just six months after.

Falcon 1’s 5th and final flight, July 2009. (SpaceX)

With three years and five successful launches under its belt, Falcon 9 v1.0 was retired and made way for the first of many upgraded Falcon 9 variants, known as Falcon 9 v1.1, featuring 60% greater thrust and mass at liftoff, a new octaweb layout for its nine new Merlin 1D engines, and a range of structural changes that set the stage for future attempts at booster recovery. Two and a half years after Falcon 9 v1.1’s debut and a little over five years since the first successful launch of Falcon 1, SpaceX accomplished the first successful landing of a Falcon 9’s first stage, and that booster now stands proudly outside of the company’s Hawthorne, CA headquarters.

To mark that 10th anniversary, SpaceX apparently decided to salvage a mothballed Falcon 1 stored in a junkyard, refurbishing it into something closer to its former self. Although just the first stage and a Merlin 1C engine were present, the company stationed the refurbished Falcon 1 in front the first recovered Falcon 9 booster and gave all employees an opportunity to see the duo over the course of September 28th.

 

The sheer size differential is undeniably impressive. However, a more gobsmacking statistic can be found still. Falcon 1 stands roughly 22 meters tall and would weigh around 39,000 kilograms with a full load of liquid oxygen and kerosene. While the Falcon family’s current payload fairing isn’t nearly tall enough to squeeze in a full Falcon 1 first stage, Falcon Heavy could easily place a fully-loaded Falcon 1 into Low Earth Orbit and still recovery all three of its first stage boosters.

In other words, SpaceX went from launching the first commercial liquid-fuel rocket to reach orbit to launching a super-heavy rocket that could put that entire first rocket into orbit in less than ten years. Not too shabby.


For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet check out our brand new LaunchPad and LandingZone newsletters!

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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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