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SpaceX Falcon 9 “Block 5” next-gen reusable rocket spied in Texas test site
SpaceX’s next and final generation of Falcon rockets is nearly ready to complete its biggest milestone yet, second only to operational launch. Known as Falcon 9 Block 5, the upgraded booster arrived at SpaceX’s McGregor, TX test facilities and went vertical on the static fire test stand.
Now vertical, that first integrated static fire is likely to occur within a handful of days at most. Once complete, assuming the data it produces do not betray any bugs or serious problems, the booster will be brought horizontal and transported to one of SpaceX’s three launch facilities for its first operational mission.
Why Block 5?
With nary a hint of hyperbole, it’s safe to say that Falcon 9 Block 5 will be the most significant piece of hardware ever developed and fielded by SpaceX. The reason lies in many of the changes and upgrades present in this newest iteration of the rocket. While Falcon 9 B5 and its similarly upgraded Merlin 1D engines include design changes intended to satisfy NASA requirements before SpaceX can be certified to launch humans, the brunt of the upgrades are laser-focused on ease and speed of reusability.
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- SpaceX Block 5 Falcon9 at McGregor, Texas [Credit: Chris G – NSF via Twitter, Reprinted with permission from NASASpaceflight.com]
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- SpaceX Block 5 Falcon9 at McGregor, Texas [Credit: Chris G – NSF via Twitter, Reprinted with permission from NASASpaceflight.com]
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- SpaceX Block 5 Falcon9 at McGregor, Texas [Credit: Chris G – NSF via Twitter, Reprinted with permission from NASASpaceflight.com]
Photo courtesy of Chris G at nasaspaceflight.com via Twitter. Reprinted with permission.
The goal with those upgrades, as publicly stated by numerous SpaceX executives, is to enable as many as 10 flights with a bare minimum of refurbishment and 100 or more launches with intermittent maintenance. To achieve those titanic aspirations, SpaceX has gathered a flood of data and experience earned through the recovery of nearly 20 Falcon 9 and Heavy boosters, as well as the successful reflight and second recovery of several of those same boosters. With that data in hand, the company’s launch vehicle engineers optimized and upgraded the rocket’s design to combat the worst of the extreme forces each booster is subjected to while returning to land (or sea).
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- Falcon Heavy side booster B1025 gives a sense of the sheer brutality of reentry conditions. (Tom Cross)
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- Note the pieces of cork that have been torn off by the buffeting and heat on the lefthand side. (Tom Cross)
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- An incredibly detail shot of the side of the octaweb. The large chunk of smooth metal in the center is actually one of the booster’s connection points to the Falcon Heavy center core. (Tom Cross/Teslarati)
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- A beautiful capture of one of the booster’s nine Merlin engines, showing off the pipe used to cool the engine bell, as well as the ceramic blanket that protects its more sensitive plumbing. (Tom Cross/Teslarati)
As evidenced by photos taken by Gary Blair, one of NASASpaceflight.com‘s most renowned L2 forum contributors, many of the visible differences between Block 5 and previous versions of Falcon 9 are a result of drastically improved and expanded heat shielding of its most sensitive and crucial components. While Falcon 9 B5’s black sections by all appearances look like naked carbon fiber composite, they are likely to be coated with an incredibly heat-resistant material known a Pyron. Portions of the booster that suffer from incidental scorching and extreme heating (aside from the octaweb) appear to have been treated with this material, including a pathway down the side of the rocket known as a raceway. The raceway is a protective enclosure for a variety of cabling and piping, essentially the rocket’s nervous system as well as the home of several the cold gas thrusters it uses to orient itself outside of Earth’s atmosphere.
In the past, SpaceX has used high-quality cork as a quasi-ablative thermal protection system for those same components, including the payload fairing. A major downside of cork, however, is that it is very ablative and tends to come off rather haphazardly in large chunks, all of which must either be spot-fixed or replaced entirely before a booster reflight. By replacing that cork with Pyron or a similar internally-developed material, those sensitive Falcon components may be almost totally insulated from and resistant to temperatures as high as 2300 °F (1200 °C)
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- Block 5 looks similar to this Falcon 9, but with a deep black interstage and a black enclosure instead of the white covering seen running down the left side of the booster. (SpaceX)
Titanium grid fins are another central feature of Block 5, acting as a near-indefinitely reusable replacement for the aluminum grid fins SpaceX has traditionally used. Put through a huge amount of heating during reentry; aluminum grid fins have famously appeared to partially melt during some of the hottest booster recovery attempts. Titanium, a metal with a much higher melting point, will have no such problems, does not need ablative white paint, and certainly appear all but untouched by reentry in the cases of both their June 2017 debut and second flight on Falcon Heavy’s side boosters.
Finally and perhaps most importantly, is the octaweb – the assembly at the base of Falcon 9 responsible for safely transmitting nearly two million pounds of thrust from its nine Merlin 1Ds to the rest of the rocket’s structure, while also taking the brunt of the heat of reentry. Before Block 5, the octaweb was protected from that heating with an ablative thermal protection system, likely around 80% cork and 20% PICA-X, the same material used on Cargo Dragon’s heat shield. Based on comments made privately by individuals familiar with SpaceX, that ablative shielding is to be replaced by a highly heat-resistant metal alloy known as inconel. By ridding Block 5 of ablative heat shielding, SpaceX will no longer have to carefully examine and replace those materials after each launch, removing one of the biggest refurbishment time-sinks.
Titanium grid fins complete the highly reusable changes to Block 5 of Falcon 9. (NASA)
Combined, these various upgrades are intended to enable Falcon 9’s first stage to be reused almost effortlessly compared to previous iterations. With this vehicle, including the reusable fairing debuted on the launch of PAZ, SpaceX may well be able to achieve Elon Musk’s famous goal of lowering the cost of launch by nearly an order of magnitude. While SpaceX will likely use that cost reduction to first recoup its considerable investments in reusability and Falcon Heavy, major price drops may reach customers soon after. This Falcon 9, in particular, is unlikely to launch for another month or so, but when it does, it is perhaps the biggest step SpaceX has yet taken on the path to routine, rapid, and affordable access to orbit.
Teslarati – Instagram – Twitter
Tom Cross – Twitter
Pauline Acalin – Twitter
Eric Ralph – Twitter
News
Tesla launches ultra-fast V4 Superchargers in China for the first time
Tesla has V4 Superchargers rolling out in China for the first time.
Tesla already has nearly 12,000 Supercharger piles across mainland China. However, the company just initiated the rollout of the ultra-fast V4 Superchargers in China for the first time, bringing its quick-charging piles to the country for the first time since their launch last year.
The first batch of V4 Superchargers is now officially up and running in China, the company announced in a post on Chinese social media outlet Weibo today.
The company said in the post:
“The first batch of Tesla V4 Superchargers are online. Covering more service areas, high-speed charging is more convenient, and six-layer powerful protection such as rain and waterproof makes charging very safe. Simultaneously open to non-Tesla vehicles, and other brands of vehicles can also be charged. There are more than 70,000 Tesla Superchargers worldwide. The charging network layout covers 100% of the provincial capitals and municipalities in mainland China. More V4 Superchargers will be put into use across the country. Optimize the charging experience and improve energy replenishment efficiency. Tesla will accompany you to the mountains, rivers, lakes, and seas with pure electricity!”
The first V4 Superchargers Tesla installed in China are available in four cities across the country: Shanghai, Zhejiang, Gansu, and Chongqing.
Credit: Tesla China
Tesla has over 70,000 Superchargers worldwide. It is the most expansive and robust EV charging network in the world. It’s the main reason why so many companies have chosen to adopt Tesla’s charging connector in North America and Europe.
In China, some EVs can use Tesla Superchargers as well.
The V4 Supercharger is capable of charging vehicles at speeds of up to 325kW for vehicles in North America. This equates to over 1,000 miles per hour of charging.
Elon Musk
Elon Musk hints at when Tesla could reduce Safety Monitors from Robotaxi
Tesla could be reducing Safety Monitors from Robotaxi within ‘a month or two,’ CEO Elon Musk says.
Elon Musk hinted at when Tesla could begin reducing Safety Monitors from its Robotaxis. Safety Monitors are Tesla employees who sit in the front passenger seat during the driverless rides, and are there to ensure safety for occupants during the earliest rides.
Tesla launched its Robotaxi fleet in Austin last Sunday, and after eight days, videos and reviews from those who have ridden in the driverless vehicles have shown that the suite is safe, accurate, and well coordinated. However, there have been a few hiccups, but nothing that has put anyone’s safety in danger.
A vast majority — close to all of the rides — at least according to those who have ridden in the Robotaxi, have been performed without any real need for human intervention. We reported on what was the first intervention last week, as a Safety Monitor had to step in and stop the vehicle in a strange interaction with a UPS truck.
Watch the first true Tesla Robotaxi intervention by safety monitor
The Tesla and UPS delivery truck were going for the same street parking space, and the Tesla began to turn into it. The UPS driver parallel parked into the spot, which was much smaller than his truck. It seemed to be more of an instance of human error instead of the Robotaxi making the wrong move. This is something that the driverless cars will have to deal with because humans are aggressive and sometimes make moves they should not.
The Safety Monitors have not been too active in the vehicles. After all, we’ve only seen that single instance of an intervention. There was also an issue with the sun, when the Tesla braked abnormally due to the glare, but this was an instance where the car handled the scenario and proceeded normally.
With the Robotaxi fleet operating impressively, some are wondering when Tesla will begin scaling back both the Safety Monitors and Teleoperators that it is using to ensure safety with these early rides.
CEO Elon Musk answered the inquiry by stating, “As soon as we feel it is safe to do so. Probably within a month or two.”
As soon as we feel it is safe to do so.
Probably within a month or two. We continue to improve the Tesla AI with each mile driven.
— Elon Musk (@elonmusk) June 30, 2025
Musk’s response seems to confirm that there will be fewer Teleoperators and Safety Monitors in the coming months, but there will still be some within the fleet to ensure safety. Eventually, that number will get to zero.
Reaching a point where Tesla’s Robotaxi is driverless will be another significant milestone for the company and its path to fully autonomous ride-sharing.
Eventually, Tesla will roll out these capabilities to consumer-owned vehicles, offering them a path to generate revenue as their car operates autonomously and completes rides.
For now, Tesla is focusing on perfecting the area of Austin where it is currently offering driverless rides for just $4.20 to a small group of people.
News
Tesla sees explosive sales growth in UK, Spain, and Netherlands in June
In countries like the UK, Spain, and the Netherlands, Tesla’s June sales surged significantly compared to May.
After months of declining deliveries and market pressure, Tesla appears to be regaining its footing in Europe. Tesla saw a significant spike in electric vehicle registrations across several key markets in June, signaling renewed momentum for the EV maker.
In countries like the UK, Spain, and the Netherlands, Tesla’s June sales surged significantly compared to May.
Explosive growth in the UK, Spain, and the Netherlands
Tesla’s most notable performance came in the United Kingdom, where June registrations jumped 224% month-over-month, and Spain, where registrations more than tripled. This made Tesla the top-selling electric car brand for the month in both countries, as per a CarUp report.
The Netherlands saw Tesla become the best-selling car brand in June across all vehicle segments. Tesla’s continued success in Norway also appears to be holding steady, though full figures for the market have not yet been finalized.
These numbers suggest Tesla’s European sales slump may have been temporary, with strong demand returning amid the ramp of the new Model Y, which was largely unavailable in the first quarter.
Mixed results in Sweden but signs of progress
In Sweden, Tesla’s performance remained mixed in June. While year-over-year registrations dropped over 70% in June, the company’s market share jumped 72% compared to May. Tesla now holds an 8.6% market share in the Swedish EV market, which means that one in every twelve new electric vehicles registered in the country last month was a Tesla, as per data compiled by eu-evs.com.
So far in 2025, Tesla ranks as the fourth-largest EV brand in Sweden, with 3,461 vehicles registered, trailing Volkswagen, Volvo, and Kia. The Tesla Model Y has remained a strong seller, ranking as the third most registered electric vehicle this year, behind the Volkswagen ID.7 and Volvo XC40, despite being largely absent in Q1 2025.
Tesla launches ultra-fast V4 Superchargers in China for the first time
Elon Musk hints at when Tesla could reduce Safety Monitors from Robotaxi
Tesla sees explosive sales growth in UK, Spain, and Netherlands in June
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