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SpaceX’s first ever Block 5 booster gives one last hurrah, in photos
After helping SpaceX enter a new era of routine rocket reusability, the very first Falcon 9 Block 5 booster is officially nothing more than bits, pieces, and a few artificial reefs at the bottom of the Atlantic Ocean — intentionally destroyed to give SpaceX the confidence it needs to soon launch astronauts.
Captured on camera by Teslarati photographer Richard Angle, the upgraded Falcon 9 booster was able to give one last spectacular hurrah prior to its even more spectacular demise, returning fire to Kennedy Space Center (KSC) Launch Complex 39A for the first time in more than half a year. Lacking landing legs and grid fins, visible instead as comically stark outlines on the booster’s sooty exterior, Falcon 9 B1046 lifted off for the fourth and final time on January 19th, 2020.
In doing so, B1046 became the third orbital-class booster ever to fly launch four separate missions — a more than fitting end to the first in a line of upgraded Falcon 9 rockets that have brought with them major improvements in reusability and reliability. Nevertheless, a little over 90 seconds after lifting off for the fourth time, Falcon 9 B1046 – left behind after Crew Dragon successfully escaped the (simulated) failing rocket – yielded under intense off-nominal stresses, rupturing the booster’s propellant tanks and creating a vast fireball at least 300 meters (1000+ ft) in diameter.
Powered by nine Merlin 1D engines and capable of producing up to 7600 kN (1.7 million lbf) of thrust, Falcon 9 B1046 was extensively tested at SpaceX’s McGregor, Texas development facilities over a period of two or so months – unusually lengthy. The extra time was used to make sure that the first completed Block 5 booster – representing an almost clean-slate upgrade of the Falcon rocket family – was agreeing with SpaceX’s engineering models and expectations at all points.
The company likely spent several weeks or more performing numerous wet dress rehearsals (WDRs) — filling Falcon 9 B1046’s propellant tanks with liquid oxygen, refined kerosene (RP-1), helium, and nitrogen and verifying that the rocket was structurally sound and functioning smoothly. Once complete, SpaceX moved onto static fire testing, igniting the booster’s M1D engines for increasing periods of time. Finally, the company wrapped up the rocket and shipped it by road from Texas to Florida.
Shortly thereafter, the rocket was quickly prepared for flight and became the first Falcon 9 Block 5 booster to successfully launch and land in May 2018. Over the course of 2018, SpaceX debuted another five Block 5 boosters, while Falcon 9 B1046 became the first Block 5 booster to launch both twice and three times in August and December.
Finally, on January 19th, 2020, Falcon 9 B1046 lifted off for the fourth and last time, becoming the third SpaceX booster to do so in barely two months. Fittingly, B1046’s last launch occurred at Pad 39A, the same launch site it lifted off from for the first time back in May 2018. Carrying an expendable upper stage, Dragon trunk, and Crew Dragon capsule C205, B1046 could not have experienced a more perfect 90 or so seconds of uninterrupted flight. Interrupted, however, it would shortly thereafter become.
Around 85 seconds after liftoff, Falcon 9 B1046 shut off its Merlin 1D engines at the same time as Crew Dragon C205 ignited eight SuperDraco engines, briskly carrying the spacecraft several thousand feet away in just a handful of seconds. Now fully uncontrolled and rudely interrupted to a supersonic wall of air, B1046 found itself bent and contorted in ways – and under loads – it simply was not designed to survive. Seconds later, the booster’s pressurized propellant tanks were breached, releasing a rapidly dispersing cloud of fuel and oxidizer that almost instantly ignited, creating a fireball the size of several city blocks.
All things considered, not a bad way to go for a well-worn rocket.
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Tesla confirms that it finally solved its 4680 battery’s dry cathode process
The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years.
The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Dry cathode 4680 cells
In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.
The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”
Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.
4680 packs for Model Y
Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla:
“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”
The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.
Elon Musk
Tesla Giga Texas to feature massive Optimus V4 production line
This suggests that while the first Optimus line will be set up in the Fremont Factory, the real ramp of Optimus’ production will happen in Giga Texas.
Tesla will build Optimus 4 in Giga Texas, and its production line will be massive. This was, at least, as per recent comments by CEO Elon Musk on social media platform X.
Optimus 4 production
In response to a post on X which expressed surprise that Optimus will be produced in California, Musk stated that “Optimus 4 will be built in Texas at much higher volume.” This suggests that while the first Optimus line will be set up in the Fremont Factory, and while the line itself will be capable of producing 1 million humanoid robots per year, the real ramp of Optimus’ production will happen in Giga Texas.
This was not the first time that Elon Musk shared his plans for Optimus’ production at Gigafactory Texas. During the 2025 Annual Shareholder Meeting, he stated that Giga Texas’ Optimus line will produce 10 million units of the humanoid robot per year. He did not, however, state at the time that Giga Texas would produce Optimus V4.
“So we’re going to launch on the fastest production ramp of any product of any large complex manufactured product ever, starting with building a one-million-unit production line in Fremont. And that’s Line one. And then a ten million unit per year production line here,” Musk stated.
How big Optimus could become
During Tesla’s Q4 and FY 2025 earnings call, Musk offered additional context on the potential of Optimus. While he stated that the ramp of Optimus’ production will be deliberate at first, the humanoid robot itself will have the potential to change the world.
“Optimus really will be a general-purpose robot that can learn by observing human behavior. You can demonstrate a task or verbally describe a task or show it a task. Even show it a video, it will be able to do that task. It’s going to be a very capable robot. I think long-term Optimus will have a very significant impact on the US GDP.
“It will actually move the needle on US GDP significantly. In conclusion, there are still many who doubt our ambitions for creating amazing abundance. We are confident it can be done, and we are making the right moves technologically to ensure that it does. Tesla, Inc. has never been a company to shy away from solving the hardest problems,” Musk stated.
Elon Musk
Rumored SpaceX-xAI merger gets apparent confirmation from Elon Musk
The comment follows reports that the rocket maker is weighing a transaction that could further consolidate Musk’s space and AI ventures.
Elon Musk appeared to confirm reports that SpaceX is exploring a potential merger with artificial intelligence startup xAI by responding positively to a post about the reported transaction on X.
Musk’s comment follows reports that the rocket maker is weighing a transaction that could further consolidate his space and AI ventures.
SpaceX xAI merger
As per a recent Reuters report, SpaceX has held discussions about merging with xAI, with the proposed structure potentially involving an exchange of xAI shares for SpaceX stock. The value, structure, and timing of any deal have not been finalized, and no agreement has been signed.
Musk appeared to acknowledge the report in a brief reply on X, responding “Yeah” to a post that described SpaceX as a future “Dyson Swarm company.” The comment references a Dyson Swarm, a sci-fi megastructure concept that consists of a massive network of satellites or structures that orbit a celestial body to harness its energy.
Reuters noted that two entities were formed in Nevada on January 21 to facilitate a potential transaction for the possible SpaceX-xAI merger. The discussions remain ongoing, and a transaction is not yet guaranteed, however.
AI and space infrastructure
A potential merger with xAI would align with Musk’s stated strategy of integrating artificial intelligence development with space-based systems. Musk has previously said that space-based infrastructure could support large-scale computing by leveraging continuous solar energy, an approach he has framed as economically scalable over time.
xAI already has operational ties to Musk’s other companies. The startup develops Grok, a large language model that holds a U.S. Department of Defense contract valued at up to $200 million. AI also plays a central role in SpaceX’s Starlink and Starshield satellite programs, which rely on automation and machine learning for network management and national security applications.
Musk has previously consolidated his businesses through share-based transactions, including Tesla’s acquisition of SolarCity in 2016 and xAI’s acquisition of X last year. Bloomberg has also claimed that Musk is considering a merger between SpaceX and Tesla in the future.
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
Tesla Giga Texas to feature massive Optimus V4 production line
