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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.

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.

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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.

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.

Follow us for live updates, peeks behind the scenes, and photos from Teslarati’s East and West Coast photographers.

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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 top exec Tom Zhu highlights Elon Musk’s “prime directive” for FSD

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Credit: Tesla AI/X

Tesla Senior Vice President for Automotive Tom Zhu, a key executive behind the company’s success in China and Giga Texas, recently highlighted the “prime directive” of Full Self-Driving (FSD).

Zhu’s comments emphasize Tesla’s uncompromising focus on safety, which has made the company’s vehicles among the safest on the road.

Echoing Musk’s vision for safe autonomous driving

Zhu’s post quoted Musk’s statement from 2021, where the CEO reportedly stated that FSD must avoid accidents even if the most ridiculous events happened in the middle of the road. Zhu stated that beyond everything, Tesla’s systems like Autopilot and FSD are designed to keep passengers safe.

“Elon said it in 2021: “For self-driving, even if the road is painted completely wrong and a UFO lands in the middle of the road, the car still cannot crash and still needs to do the right thing. The prime directive for the autopilot system is: Don’t crash. That really overrides everything. No matter what the lines say or how the road is done, the thing that needs to happen is minimizing the probability of impact while getting you to your destination conveniently and comfortably,” Zhu stated.

“The prime directive, the absolute priority, is to minimize the probability of injury to yourself or to anyone on the road, to pedestrians, or anything like that. It can’t be dependent on the road markings being correct.”

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Tesla leadership rallies behind global FSD rollout

Tom Zhu, who previously led Tesla China through its record-breaking growth phase, now oversees automotive operations worldwide. He has reportedly become a problem solver for Elon Musk over the years, with previous reports stating that he was brought in to help Giga Texas optimize its vehicle production ramp.

Zhu’s comments may sound ambitious, but FSD has proven that it values safety above all else over the years. This was highlighted recently in an incident in Australia, when a Model Y was hit by what could very well be a meteor. Despite the impact and part of its windshield melting, the vehicle was able to drive safely and keep its passengers safe.

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Elon Musk’s biggest tech rival just canceled his Tesla Roadster

“I really was excited for the car! And I understand delays. But 7.5 years has felt like a long time to wait,” Altman said.

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Tesla Roadster at Tesla Battery Day 2020 Credit: @BLKMDL3 | Twitter

Elon Musk’s biggest tech rival just canceled his reservation for a Tesla Roadster, the supercar the company has been developing for nearly eight years.

Sam Altman, the CEO of OpenAI, announced on X on Thursday evening that he canceled his Tesla Roadster reservation, or at least is trying to:

Altman placed his Tesla Roadster reservation with a $50,000 deposit way back on July 11, 2018. However, he recently decided that he had waited long enough and decided to email the company to officially cancel the order.

“Hi, I’d like to cancel my reservation. Could you please refund me the $50k?” Altman emails to reservations@tesla.com.

He then received an immediate response, but not from Tesla. Instead, it was a bounce-back message from Google, stating that the message could not be delivered to the email because it was not active.

Altman then provided a reason for his cancellation, and it was not related to the intense rivalry he had with Elon Musk:

“I really was excited for the car! And I understand delays. But 7.5 years has felt like a long time to wait.”

Altman and Musk have a lengthy history with one another that dates back to 2015, when OpenAI was created. The feud has resulted in lawsuits over breaching founding agreements by prioritizing profits.

Musk has been especially critical in recent years because of Altman’s decision to turn OpenAI into a for-profit business that he says is “built on a lie.”

This year, Musk offered over $97 billion to buy OpenAI, and a judge blocked his request to stop the company from being converted into a for-profit in March.

OpenAI then countersued Musk in April, while xAI, Musk’s company, sued OpenAI for allegedly stealing secrets through poached employees in September.

Elon Musk explains why xAI sued OpenAI over alleged trade secret theft

Regarding the Roadster, Tesla has been developing it for several years and has delayed its release for five consecutive years. The company says it will have a demo of what it has changed since it was unveiled in 2017 later this year, but no date has been set quite yet.

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Neuralink’s first human patient reflects on 21 months with brain implant “Eve”

He credited Neuralink and Elon Musk for giving him “the opportunity to be the first,” as the experience has been life-changing.

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Credit: Neuralink

Nolan Arbaugh, the first person to receive Neuralink’s brain implant, shared his 21-month update this week, reflecting on how far he’s come since his groundbreaking surgery. 

Arbaugh, who became paralyzed after a diving accident, stated that his Neuralink implant, which he fondly calls “Eve,” continues to transform his daily life.

Arbaugh celebrates Neuralink’s progress

In his post on X, Arbaugh revealed that his hands-on involvement with Neuralink has decreased as more participants have joined the program. “The team might call me to test something once in a blue moon,” he wrote, adding that he’s happy to see others experience the technology’s full potential, from operating robotic arms to typing on keyboards with thought alone.

He credited Neuralink and Elon Musk for giving him “the opportunity to be the first,” as the experience has been life-changing. Despite a recent pressure sore that temporarily kept him bedridden, Arbaugh noted that he is still very optimistic, describing his journey as one of resilience, faith, and gratitude. He also teased “big news” coming for his two-year update in early 2026.

Studies and a growing public speaking career 

These days, Arbaugh stated that he is focused on his studies in neuroscience, taking full-semester courses in chemistry, biology, and pre-calculus while earning top grades. He credited “Eve” for making school possible again, as his current academic workload would have been “impossible without Neuralink.” Arbaugh stated that he has also begun building a speaking business after delivering a paid talk at Fortune’s Brainstorm Tech conference.

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“At the beginning of September I attended the Fortune Brainstorm Tech conference in Park City, Utah, as a paid speaker. That sentence seemed like an impossibility two years ago. But it’s just the beginning. My business is built, my legal is near complete, I’m surrounding myself with a team of amazing folks, and I plan on speaking once or twice a month in the same fashion beginning as soon as January. 

“Conferences, interviews, podcasts—you name it, and I want to be there spreading the word about how amazing this technology is, the growth it’s experiencing, the possibilities of the future, and how it has so deeply affected my life,” Arbaugh stated.

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