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SpaceX’s reusable Falcon 9 fleet takes shape as rocket booster production ramps

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Per a source involved in SpaceX’s cross-country rocket transport infrastructure, the company continues to beat the expectations of its closest followers, pointing towards an inflection point in the production and testing of new Falcon 9 Block 5 rocket boosters and upper stages.

Building off of a number of Falcon 9 booster, upper stage, and fairing spottings over the past six weeks, it can reasonably be concluded that SpaceX has completed, shipped, tested (i.e. static fires in Texas), and delivered (to launch sites) as many Falcon 9 rockets in six weeks as were shipped, tested, and launched in the preceding five months – perhaps even 30% more.

This extreme production ramp can be attributed almost entirely to the maturation of Falcon 9 Block 5’s design and manufacturing apparatus, owing to the fact that the rocket’s most recent (and theoretically final) upgrade necessitated significant changes to almost every major aspect of the Falcon family. Meanwhile, a considerable amount of time and effort had to be directed towards the optimization and production of the first Falcon Heavy, to some extent an entirely bespoke rocket built off of much older Falcon 9 cores and a center core design unlikely to be repeated.

With Falcon Heavy completed and launched in February and the last non-Block 5 booster built, launched, and relaunched in the last three months, Falcon 9 Block 5 has for the first time been allowed to become SpaceX’s near-singular focus for manufacturing and testing, both in the Hawthorne factory, the McGregor, TX testing facility, and SpaceX’s three launch pads.

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This change in focus likely means that SpaceX was finally able to rid itself of what were effectively multiple SKUs (serial versions) of its workhorse rocket, presumably allowing their supplier and manufacturing apparatus to be significantly streamlined. With low-volume production and limited manufacturing space, multiple SKUs were likely a massive challenge for the Hawthorne factory and the McGregor testing facility, where the stand used to test Falcon 9 boosters likely required significant modifications to support Block 5 static fires. Meanwhile, SpaceX’s three launch pads in Florida and California all needed their own series of upgrades to transfer from Block 4 to Block 5.

 

Regardless, SpaceX has clearly gotten its manufacturing feet back under it and has ever-growing confidence in the nascent Block 5 iteration of Falcon 9. COO and President Gwynne Shotwell noted in a May 2018 CNBC interview that she believed the Hawthorne factory was nominally capable of producing one Merlin engine a day and two Block 5 boosters per month, and this recent burst of activity appears to heartily confirm her estimates. What remains to be seen is if what appears to be a six-week sprint (at least relative to the last year or so of rocket building) will instead prove to be the norm for the second half of 2018 and 2019.

If SpaceX can continue to sustain this extraordinarily rapid-fire pace of rocket production for just the next six months, the company could round out 2018 with a strong start to what Shotwell described would be a “sizable fleet” of Falcon boosters. Block 5 boosters B1047, B1048, and B1049 are now finished with static fire testing in McGregor after shipping from Hawthorne and either at launch sites or on their way, while B1050 most likely just arrived at McGregor for its own static fire. The first successfully launched and recovered Block 5 booster (B1046) was said by CEO Elon Musk to be undergoing a thorough teardown analysis – a process that almost certainly has been completed given the burst of Block 5 shipments and testing – and should be free to support additional launches later this year.

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If SpaceX continues to produce nearly two boosters per month, the company could round out 2018 with a fleet of nearly 16 Falcon 9 boosters, each of which has been designed to support anywhere from a handful to a hundred reuses.

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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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Tesla reigns supreme in the heaviest EV market on Earth

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Credit: Grok Imagine

In the global race toward electrification, Norway stands unchallenged as the world’s most mature EV market.

In the first quarter of this year, EVs captured a staggering 97.9 percent market share, with plugin EVs reaching 98.6 percent. Out of 27,175 new vehicles registered, non-BEV powertrains have been reduced to statistical noise—petrol and hybrids combined accounted for fewer than 80 units.

At the heart of this transformation is Tesla.

The Model Y dominated overall vehicle sales with 5,406 units, outselling the next five best-selling non-Tesla models combined. The refreshed Model 3 followed in second place with 2,010 units, giving Tesla a commanding one-two finish. Toyota’s bZ4X placed third with 1,400 units, while Volvo’s EX40 and others trailed further back.

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This dominance is no fluke. Norway has spent decades building the infrastructure and policy framework that makes EVs the rational choice. Generous tax incentives, exemption from VAT, reduced tolls, free ferries for EVs, and a dense charging network have turned the country into a living laboratory for mass adoption. High fuel prices—often exceeding $8 per gallon—further tilt the economics decisively toward electricity.

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The result is a market where choosing anything but an EV feels increasingly anachronistic. Diesel and petrol cars have all but vanished from new registrations. Even plug-in hybrids, once a transitional favorite, have collapsed to 0.7 percent share.

Chinese brands like XPeng, BYD, and Zeekr are making inroads, while legacy European and Japanese automakers scramble to field competitive BEVs. Yet Tesla’s combination of range, performance, software, Supercharger network, and brand cachet continues to set the benchmark.

Norway’s Q1 figures come after a volatile start to 2026 caused by VAT changes that pulled forward sales into late 2025. The market rebounded strongly in March, underscoring underlying demand. Tesla’s Q1 performance in the country also jumped significantly year-over-year, reinforcing its position even as competition intensifies.

What happens in Norway rarely stays there. The country has long served as a bellwether for EV trends across Europe and beyond.

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Its near-total transition demonstrates that when incentives align with infrastructure and consumer economics, adoption accelerates dramatically. For automakers, Norway signals a future where success hinges not on legacy powertrains but on delivering compelling electric vehicles at scale.

As other nations ramp up their own EV ambitions, Tesla’s continued reign in the world’s heaviest EV market sends a clear message: in a fully mature electric future, the company that started the revolution remains the one to beat. With the Model Y still the best-selling vehicle overall—quarter after quarter—Norway’s roads are a rolling testament to Tesla’s enduring leadership.

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Tesla owners keep coming back for more

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Tesla has taken home the “Overall Loyalty to Make” award from S&P Global Mobility for the fourth consecutive year, reinforcing Tesla owners’ willingness to come back. The 2025 awards are based on S&P Global Mobility’s analysis of 13.6 million new retail vehicle registrations in the U.S. from October 2024 through September 2025. The complete list of 2025 winners includes General Motors for Overall Loyalty to Manufacturer, Tesla for Overall Loyalty to Make, Chevrolet Equinox for Overall Loyalty to Model, Mini for Most Improved Make Loyalty, Subaru for Overall Loyalty to Dealer, and Tesla again for both Ethnic Market Loyalty to Make and Highest Conquest Percentage.

Tesla’s streak in this category started in 2022, and the brand has now won the Highest Conquest Percentage award for six straight years, meaning it keeps pulling buyers away from other brands at a rate no competitor has matched. Tesla’s retention among Asian households reached 63.6% and among Hispanic households 61.9%, rates that significantly outpace national averages for those groups. That breadth of appeal across demographics adds a layer of significance to a win that some might dismiss as routine.

The timing matters too. After several consecutive quarters of decline, Tesla’s share of U.S. EV sales jumped to 59% in Q4 2025. That rebound, arriving just as competitors were flooding the market with new models and incentives, suggests Tesla’s loyalty numbers are not simply the result of limited alternatives. Buyers are still choosing it when they have plenty of other options.

What keeps Tesla owners coming back has a lot to do with the  and convenience of charging. The Supercharger network is the most straightforward example. With over 65,000 Superchargers globally, it remains the largest and most reliable fast-charging network in the world, and owners who have built their routines around it face a real practical cost when considering a switch. Competitors have made progress, but the consistency, speed, and availability of Tesla’s network is still the benchmark the rest of the industry is chasing.  Then there is the software side. Tesla has built a model where the car you own today is functionally different from the car you bought two years ago, through over-the-air updates that add continuous game-changing improvements such as Full Self-Driving that has moved from a driver-assist feature to an increasingly capable autonomous system. For many Tesla owners, leaving the brand means starting over with a car that will not get meaningfully better over time, and that is a trade-off fewer and fewer are willing to make.

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Tesla Robotaxi service in Austin achieves monumental new accomplishment

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Credit: Tesla

Tesla Robotaxi services in Austin have been operating since last Summer, but Tesla has admittedly been delayed in its expansion of the geofence, fleet size, and other details in a bid to prioritize safety as new technology rolls out.

But those barriers are being broken with new guardrails being removed from the program.

Tesla has achieved a significant advancement in its autonomous ride-hailing program. As of May 4, the Robotaxi fleet in Austin, Texas, has begun operating unsupervised during evening hours for the first time. This expansion moves beyond previous limitations that restricted unsupervised service to daylight hours, typically ending in mid-afternoon.

The change brings Austin in line with operations in Dallas and Houston. Those cities have supported evening unsupervised runs since their initial launches in April, and both recently received additions of new unsupervised vehicles to their fleets. This coordinated progress across Texas strengthens Tesla’s regional presence and provides a broader testing ground for the technology.

This milestone carries substantial weight in the development of autonomous vehicles. Extending operations into low-light conditions meaningfully expands the Robotaxi’s operational design domain (ODD)—the specific environments and scenarios in which the system is approved to operate safely without human intervention.

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Nighttime driving presents unique technical demands: diminished visibility, headlight glare from oncoming traffic, reduced contrast for identifying pedestrians and lane markings, and greater variability in camera sensor exposure.

Tesla Cybercab just rolled through Miami inside a glass box

Tesla’s pure vision approach, powered by neural networks trained on vast real-world datasets rather than lidar or pre-mapped routes, must handle these variables reliably. Demonstrating consistent unsupervised performance after sunset validates the robustness of the end-to-end AI stack and its ability to generalize across diverse lighting conditions.

Beyond technical validation, the expansion holds important operational and economic implications. Evening hours often coincide with peak urban demand for rides, including commutes, dining, and entertainment outings.

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Enabling service during these periods increases daily vehicle utilization, allowing each Robotaxi to generate more revenue while gathering additional high-value training data. Higher utilization accelerates the virtuous cycle of data collection, model improvement, and further ODD growth.

Looking ahead, this step paves the way for more ambitious rollouts. Success in low-light environments positions Tesla to pursue near-24-hour operations, potentially integrating highways and expanding into varied weather patterns. Regulators worldwide frequently demand evidence of safe performance across day-night cycles before granting wider approvals.

Proven capability in Texas could expedite deployments in planned cities such as Phoenix, Miami, Orlando, Tampa, and Las Vegas during the first half of 2026.

Tesla confirms Robotaxi expansion plans with new cities and aggressive timeline

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Moreover, scaling evening service supports Tesla’s long-term vision of a high-efficiency robotaxi network. Greater fleet productivity lowers the cost per mile, making autonomous mobility more accessible and competitive against traditional ride-hailing.

As the company iterates on software updates informed by nighttime data, reliability is expected to compound rapidly, unlocking denser urban coverage and longer-distance trips.

In summary, the introduction of an unsupervised evening Robotaxi service in Austin represents more than an incremental schedule adjustment. It signals a critical maturation of the underlying technology and sets the foundation for broader geographic and temporal expansion.

With Texas operations gaining momentum, Tesla is steadily advancing toward transforming urban transportation at scale.

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