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SpaceX Falcon 9 “Block 5” next-gen reusable rocket spied in Texas test site

SpaceX Block 5 Falcon9 at McGregor, Texas [Credit: Chris G - NSF via Twitter]

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8 years ago

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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.

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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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)

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.

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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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Investor's Corner

Tesla analyst says this common earnings narrative is losing importance

“Numbers are going down next year, but that’s ok because it’s all about autonomy.”

Published

9 hours ago

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October 21, 2025

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(Credit: Tesla)

A Tesla (NASDAQ: TSLA) analyst is doubling down on the idea that one common earnings narrative is losing importance as the company continues to work toward new technologies and projects.

This week, Tesla will report earnings for the third quarter, and one thing people always pay attention to is deliveries. Although Tesla reveals its deliveries for the quarter well before it reports earnings, many investors will look for commentary regarding the company’s strategy for responding to the loss of the $7,500 tax credit.

Tesla has made a few moves already, including a lease deal that takes a substantial amount of money off, launching new Standard models, and cutting up to 23 percent off of lease pricing.

Tesla makes crazy move to spur short-term demand in the U.S.

However, analysts are looking at the company in a different light.

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Aligning with the narrative that Tesla is not just a car company and has many different projects, Gene Munster of Deepwater Asset Management believes many investors need to look at another part of the business.

Munster said the delivery figures for Q3, which landed at 497,099, the highest in company history, were padded by customers rushing to showrooms to take advantage of the expiring tax credit.

He believes that deliveries will be more realistic in subsequent quarters, but investors should not worry because the focus on Tesla is not going to be on how many cars it hands over to customers:

“Numbers are going down next year, but that’s ok because it’s all about autonomy.”

Tesla has been working nonstop to roll out a dedicated Robotaxi platform in various cities across the United States, and has already launched in two states: Texas and California.

It has also received regulatory approvals to test driverless Robotaxis in Arizona and Nevada, while seeking permissions in Florida and other states, according to the company’s online job postings.

Munster continued:

“Most people are hyper-focused on the Robotaxi opportunity and not focused as much on FSD.”

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While Robotaxi is incredibly important, Tesla’s Full Self-Driving (Supervised) suite is also extremely crucial moving forward, as it sets the stage for the company to roll out a formidable self-driving service.

Tesla rolled out its newest FSD software to more owners last night, and as it expands, the company is gaining valuable data to refine its performance.

Earnings will be reported tomorrow at market close.

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Tesla rolled out a new feature with FSD v14 to fix a major complaint

One of the most crucial cameras for FSD operation is located at the top of the windshield, and some owners have complained about condensation or other debris accumulating here, which impacts FSD’s availability during drives.

Published

10 hours ago

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October 21, 2025

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Credit: The Kilowatts | X

Tesla rolled out a new feature with Full Self-Driving (Supervised) v14.1.3 in an effort to fix a major complaint from owners.

Tesla’s approach to self-driving is significantly different than other companies as it only relies on cameras for operation. Tesla Vision was launched several years ago and completely axed any reliance the suite had on sensors, as CEO Elon Musk’s strategy was unorthodox and went against the grain.

However, it has proven to be effective, as Tesla still operates the most refined semi-autonomous driving suite in the United States.

There are some drawbacks, though, and one of them has to do with the obvious: cameras get dirty and need to be cleaned somewhat regularly.

One of the most crucial cameras for FSD operation is located at the top of the windshield, and some owners have complained about condensation or other debris accumulating here, which impacts FSD’s availability during drives:

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Tesla has been working to confront this issue, and in classic fashion, it used a software update to work on resolving it.

With the rollout of Full Self-Driving v14.1.3 and Software Version 2025.32.8.15, Tesla added a new feature that aims to clean the front camera efficiently without relying on the owner to do it manually.

Tesla Full Self-Driving’s new version officially gets a wider rollout

In its release notes for the suite, it said:

“Added automatic narrow field washing to provide rapid and efficient front camera self-cleaning, and optimize aerodynamics wash at higher vehicle speed.”

If the camera starts to have some issues with visibility, the car will automatically clean the front windshield camera to avoid any issues:

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This new addition is a small but mighty change considering all things. It is a necessary process to keep things operational and avoid any disruptions in FSD performance. It is also a testament to how much better Tesla vehicles can get with a simple software update.

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Tesla Full Self-Driving’s new version officially gets a wider rollout

So far, v14 has introduced a handful of new features and improvements, but the first versions needed refinement before Tesla made an effort to expand the population. It had issues with a brake stutter, but this has been mostly resolved.

Published

13 hours ago

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October 21, 2025

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Credit: Tesla Europe and Middle East | X

Tesla’s newest Full Self-Driving version is officially rolling out wider to customers outside of the Early Access Program (EAP), in preparation for a total launch of the new v14 suite.

Over the past several weeks, Tesla has been working to refine its new v14 Full Self-Driving (Supervised) in an effort to have it ready for the entire fleet of vehicles in the United States. We are lucky enough to be in the EAP, so we’ve been able to test new features and rollouts first-hand.

So far, v14 has introduced a handful of new features and improvements, but the first versions needed refinement before Tesla made an effort to expand the population. It had issues with a brake stutter, but this has been mostly resolved.

Additionally, the rollout of the new Mad Max Speed Profile has gathered some attention.

Now that Tesla has started rolling out v14.1.3 yesterday to EAP members, the company ultimately decided that it was time to expand the software to more vehicles, as many owners are reporting that they’re receiving it:

Additionally, the suite has started to expand to Model S and Model X vehicles, so this rollout is not exclusive to Model 3 and Model Y:

The only issue with this rollout is that it still appears to be missing the Cybertruck, which Tesla was transparent about earlier this month. Although the company planned to release v14 to Cybertrucks by the end of the month, there has been no hint that this is going to happen.

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This is already the third iteration of v14 in the past two weeks, indicating that Tesla is truly addressing the shortcomings of past versions and rolling out updates as quickly as possible.

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