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SpaceX rings in Falcon 9’s 10th anniversary with a rocket reusability first

Five launches, one booster. (SpaceX, SpaceX, SpaceX, Richard Angle, Richard Angle)

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Today is the tenth anniversary of SpaceX’s inaugural Falcon 9 launch, marking a decade of largely uninterrupted success that the company has rung in with a record-breaking Starlink launch and rocket landing.

Just one day shy of the occasion, booster B1049 lifted off on its fifth orbital launch and Falcon 9’s 86th launch overall, successfully placing the eighth batch of 60 SpaceX Starlink satellites in orbit and becoming the first booster ever to complete five orbital-class launches and landings. Designed to fly no fewer than 10 times each, that means that SpaceX is already half of the way to achieving a major goal of the rocket’s Block 5 upgrade just 24 months after its launch debut.

With Starlink-8 under its belt, Falcon 9 B1049 has officially become the fastest orbital-class rocket or spacecraft in history to perform five launches, beating out Space Shuttles Columbia (~27 months), Challenger (~24 months), Discovery (~22 months), Atlantis (~26 months), and Endeavour (~29 months) with launches in ~20 months. Over the 10 years it’s been operational, thanks in large part to the unprecedented leaps SpaceX has made while independently developing booster reusability, Falcon 9 has become the most affordable source of large orbital launches and has come to dominate the commercial launch market and the company’s lead is only likely to grow in the coming years.

Lifting off just hours after SpaceX completed Port Canaveral recovery operations with the first astronaut-proven Falcon 9 booster (B1058), B1049’s fifth successful launch and landing means that the company will soon be able to attempt the sixth launch of an orbital-class booster for the first time ever. All but guaranteed to support one of the 20-24 Starlink missions SpaceX has planned for 2020, B1049 could be ready for its sixth launch as early as late July or August.

(Richard Angle)
(Richard Angle)
(Richard Angle)
(Richard Angle)

Just like the booster’s two prior launches, B1049 was carrying a ~16 metric ton (~35,000 lb) batch of 60 Starlink communications satellites. Thanks to Falcon 9’s exceptional cost-to-performance ratio and the rapid expansion of Starlink launch activities, SpaceX’s workhorse rocket has already launched almost 450 metric tons (~1 million lb) of satellites and cargo into orbit over 10 years of service and 85 launches.

If things go according to plan, the Starlink launch campaign SpaceX needs to complete the massive satellite constellation will rapidly double (and almost triple) the total mass SpaceX has placed in orbit. The first major phase of 4400 satellites – currently 9.5% complete – will collectively weigh more than 1100 metric tons (~2.5 million lb), while the combined second and third phases will raise that by almost a full magnitude. Falcon 9 may forever be famous thanks to the leaps it’s made in reusability, affordability, and reliability, but it will likely end up being best known for its foundational role in the deployment of SpaceX’s vast Starlink internet constellation within a few years.

(Richard Angle)
(Richard Angle)

After B1049.5 safely returns to Port Canaveral aboard drone ship Just Read The Instructions (JRTI) sometime next week, SpaceX can offload the rocket, transport it to a nearby hangar, and begin preparing it for launch #6 – a first for the company. If SpaceX can average 90-day turnarounds for the booster over its next several flights, B1049 could potentially become the first Falcon 9 first stage to achieve its 10-flight design goal before the end of next year.

Meanwhile, SpaceX is already preparing to launch its next (ninth) Starlink mission as early as June 12th, beating the pad’s current turnaround record by almost three days (~25%). All things considered, a full decade in, SpaceX and its Falcon 9 rocket are just getting started.

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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.

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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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.

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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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.

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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