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SpaceX’s Falcon 9 Block 5 ready for first Return-To-Launch-Site booster landing

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Falcon 9 B1048.2 is vertical at SpaceX’s Vandenberg Space Launch Complex 4 (SLC-4) facilities ahead of the rocket’s second launch, targeted at 07:21 PM PDT, Oct. 7 (02:21 UTC, Oct. 8). A bit less than ten minutes after liftoff, B1048 will attempt a Return-To-Launch-Site (RTLS) landing just ~1400 feet from the launch pad.

Meanwhile, Mr. Steven is ready to depart Port of San Pedro in support of Falcon fairing recovery operations soon after liftoff, the vessel’s fifth attempted catch in ~12 months of active service with SpaceX.

A few hours after the vessel’s four arms and net were fully installed (the first time in more than six weeks), SpaceX technicians performed a series of last-minute tests with a Falcon fairing half placed on his net to verify that its mechanised rigging was working as intended, while also double-checking data connectivity between the fairing and its target (the net). Pre-launch checkouts largely completed, Mr. Steven now has to travel a short 200 miles to reach the region where SpaceX expects Falcon 9’s fairings to be recovered.

Of Falcons and fairings

It may feel quite different watching in real time, but SpaceX has made a huge amount of progress towards successful and routine fairing recoveries over the course of the last year and a half. Before the company became truly famous (and popular), more than two years (2013-2015) and a dozen distinct attempts were spent patiently learning how to recover Falcon 9 boosters, ranging from the first launch of Falcon 9 V1.1 (CASSIOPE, late 2013) to multiple instances where boosters exploded in spectacular fashions on drone ships Just Read The Instructions and Of Course I Still Love You after SpaceX began true landing attempts.

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In fact, the first intact recovery didn’t even take place on a drone ship after years of extensive testing at sea – in December 2015, after separating from its Orbcomm-2 satellite constellation payload, Falcon 9 B1019 became the first booster recovered by SpaceX in one piece, landing almost flawlessly at the company’s just-finished Cape Canaveral landing zone, known as LZ-1. Several months later, SpaceX successfully recovered its first Falcon 9 at sea, landing a booster on OCISLY shortly after launching the CRS-8 Cargo Dragon mission, although several more failures or near-failures followed as recovery technicians and engineers worked through a diverse and unpredictable series of challenges as they arose.

Rocket recovery: it’s not easy

Even in 2018, SpaceX unintentionally expended Falcon Heavy’s center core, demonstrating that even three dozen successful Falcon 9 and Heavy booster recoveries are not necessarily enough to shine light on or predict all possible modes of failure. Around 7:21 PM (PDT) today, barring a scrubbed launch attempt, the already-flown Falcon 9 booster B1048 – refurbished from landing to launch in just ~74 days – will likely launch and land once more, and most of the world wont even blink and eye. In the eyes of those that don’t or haven’t followed SpaceX obsessively, rocket booster recovery and reuse is to some extent already perceived as routine, logical, and inevitable less than three years after the technology’s first true Kitty Hawk moment.

 

The point of this brief SpaceX history lesson is to emphasize that fairing recovery is an extremely young technology, even for SpaceX. Before Mr. Steven swooped into existence, SpaceX had begun attempting to softly land payload fairings in the ocean around the start of 2017, and Mr. Steven famously returned to Port of San Pedro with an intact (but unreusable) fairing half in March 2018 after successfully launching Earth-imaging satellite PAZ. Comparing historical apples to present-day oranges, it may be safe to assume that fairing recovery’s Orbcomm-2 moment – Mr. Steven’s first successful catch – is already on the horizon.

In the meantime, it never hurts to remind oneself that – vicarious frustrations aside – observers are likely watching history unfold in real-time once again. SpaceX’s SAOCOM-1A launch webcast will begin around 7PM PDT – 15 or 20 minutes prior to launch – and can be found at the link below.

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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!

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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Investor's Corner

SpaceX reveals how its 1 Million AI satellite network will work and prevent space collisions

SpaceX reveals plans for one million Starmind AI satellites and calls out operators hiding maneuvers.

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Concept rendering of SpaceX Starmind constellation via Grok
Concept rendering of SpaceX Starmind constellation via Grok

SpaceX has put the largest satellite count it has ever published into writing, and it says that plan only works if every other operator in orbit starts sharing what it knows.

In a new Space Safety page highlighted Tuesday morning by Sawyer Merritt on X, SpaceX said it “plans to operate up to 100,000 Starlink satellites and up to 1 million Starmind AI satellites to meet the growing demand for broadband and supercompute.” Starlink has a little over 11,000 satellites in orbit today, so the target alone implies roughly a ninefold expansion of the broadband network.

Starmind is SpaceX’s orbital AI compute constellation. Elon Musk confirmed the Starmind name in June after an xAI trademark filing surfaced, and in August SpaceX said it was working with Nvidia on the compute payload. The FCC accepted the filing for up to one million satellites back in February.

FCC accepts SpaceX filing for 1 million orbital data center plan

SpaceX also released a new render of what a full Starmind constellation could look like. Alongside it, SpaceX VP Michael Nicolls explained why the satellites will not operate on their own. “We need to operate clusters of satellites in tight formation to get enough coherent compute to run AI models efficiently,” Nicolls said. “A cluster will be 10-ish satellites connected with 10 terabits or so of bandwidth between them, and interconnected to the broader constellation.”

That is the most specific detail SpaceX has given on how Starmind will be built. Instead of a million independent servers, the network would work as tightly packed groups of about 10 satellites acting as one compute unit, with Starlink’s laser links carrying results back to Earth.

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Packing satellites that close together, at that scale, makes collision avoidance the central problem, and most of the Space Safety page is aimed at other operators. SpaceX said Starlink encountered collision risks with about 650 unique maneuvering third party satellites in 2026, and only about half of them shared data. Over six months, Starlink recorded roughly 164,000 more collision risks where the closest approach came within four hours of an unannounced maneuver.

Some operators keep maneuver plans private over proprietary concerns, while others cannot get government permission to share them. SpaceX called those policies “counterproductive,” saying they “largely only serve to create preventable collision risk between satellites.” Starlink is also offering a free ephemeris sharing and screening platform that returns risk results within a minute, backed by its Stargaze network of 30,000 optical sensors.

The push comes as the Starmind application draws opposition from astronomers and environmental groups. In a September filing with the FCC, SpaceX said each Starmind satellite could weigh up to 4,000 kg, nearly seven times the mass of a Starlink V2 Mini. Musk has brushed off crowding concerns before, telling viewers in June that “space is enormous” and that SpaceX already knows how to run very large constellations safely.

SpaceX’s Starmind page says its Gigasat factory in Bastrop, Texas, is designed to produce AI satellites at scale, with deployment of thousands of units starting as soon as late 2027.

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SpaceX just locked up a NASA record no other U.S. spacecraft can touch

SpaceX’s Crew-13 Dragon reached the ISS in under eight hours, and NASA confirmed a record.

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SpaceX now owns every spot on the list of the five fastest trips a U.S. spacecraft has ever made to the International Space Station, and its newest entry beat the old mark by more than four hours.

Crew Dragon Grace docked to the forward port of the station’s Harmony module at 7:05 p.m. ET on October 1, just 7 hours and 55 minutes after lifting off from Space Launch Complex 40 at Cape Canaveral. NASA confirmed the milestone in a space station blog update, writing that the flight “marked the fastest launch‑to‑docking of a U.S. spacecraft in the history of the International Space Station.”

The previous U.S. record also belonged to Dragon. SpaceX’s uncrewed CRS-31 cargo mission reached the station in a little over 12 hours in November 2024. The fastest crewed trip before last week was Crew-11, which took 14 hours and 43 minutes in August 2025, according to Space.com.

A post that Elon Musk reposted on Monday filled out the rest of the ranking. Behind Crew-13, CRS-31 and Crew-11 sit Axiom’s Ax-2 mission at 15 hours and 35 minutes and NASA’s Crew-4 at 15 hours and 44 minutes. All five flew on Dragon.

SpaceX turned a heralding moment for Starship into its greatest

Crew-13 carried NASA astronauts Jessica Watkins and Luke Delaney, Canadian Space Agency astronaut Joshua Kutryk, and Roscosmos cosmonaut Sergey Teteryatnikov. NASA had projected a docking around 8 p.m. ET, as Teslarati reported the day before launch, and Dragon arrived nearly an hour early. Our launch day coverage noted that the flight was lined up to be the quickest Crew Dragon transit yet.

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The speed came from timing more than hardware. SpaceX’s Julianna Scheiman said the station “was in an opportune spot in space,” which let Dragon start closing the gap almost immediately after reaching orbit. “This is close to the fastest it could be,” she added. Most Crew Dragon flights still take close to a day, using a series of Draco thruster burns to raise and phase their orbit before arrival.

Dragon’s next job at the station is a departure. NASA said Monday it is targeting 8:05 a.m. ET on Wednesday, October 7, for Crew-12 to undock, setting up a splashdown off the coast of California around 11:34 a.m. on Thursday. Clearing that port makes room for CRS-35, a cargo Dragon carrying the final set of iROSA solar arrays.

Dragon remains NASA’s only operational ride to the station while Boeing’s Starliner stays grounded, and the agency recently added Crew-15, Crew-16 and Crew-17 to SpaceX’s contract in a $946 million modification.

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Elon Musk teases TSMC as potential Terafab partner

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SpaceX Terafab rendering
SpaceX Terafab rendering

Elon Musk has acknowledged that early discussions with Taiwan Semiconductor Manufacturing Company (TSMC) could bring the company into his ambitious Terafab semiconductor project, signaling a possible partnership with the world’s leading contract chipmaker.

Musk confirmed that early talks are underway, but as of right now, they are “just discussions.” There is no confirmation of a deal nor dismissal of the possibility of one, leaving open the prospect of one of the largest advanced-chip collaborations under discussion in the U.S.

The report that speculated on potential discussions between Terafab and TSMC comes from Tim Culpan, who outlined a few ways the collaboration could operate. One is TSMC using the project as an “anchor customer” for future facilities in Texas, potentially contributing process expertise, operational know-how, or capacity while Terafab provides capital, long-term purchase commitments, or both.

Tesla and SpaceX jointly developed the Terafab project, with Intel already participating on the tech side. Elon Musk announced the project in March, and it intends to produce more than one terawatt of AI compute capacity annually once fully built.

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Elon Musk’s Terafab project locks up massive new partner

Company statements place the first phase at approximately $16.8 billion in cost, with later filings pointing to a total that could reach well into the tens of billions across multiple stages.

Intel joined the effort in April 2026 and is expected to supply its 14A manufacturing process for the full-scale plant.

Musk has said existing suppliers, including Samsung and TSMC, remain important for near-term needs; Tesla already has production arrangements with Samsung for AI5 and AI6 chips, but that future demand from Optimus robots, Cybercab vehicles, and planned space-based data centers will eventually exceed what the global industry can currently deliver.

Terafab is positioned as the long-term answer to that projected shortfall, and Tesla did something similar during COVID to avoid a chip shortage. This is just a much larger-scale solution.

If the partnership were to materialize, it would add TSMC’s industry-leading strategies to a project that already combines Tesla’s and SpaceX’s capital and offtake with Intel’s process technology. For now, the only public confirmation is Musk’s brief acknowledgement that conversations are occurring.

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