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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
In Pennsylvania, we got between 10 and 12 inches of snow over the weekend as a nasty Winter storm ripped through a large portion of the country, bringing snow to some areas and nasty ice storms to others.
I have had a Model Y Performance for the week courtesy of Tesla, which got the car to me last Monday. Today was my last full day with it before I take it back to my local showroom, and with all the accumulation on it, I decided to run a cool little experiment: How long would it take for Tesla’s Defrost feature to melt 8 inches of snow?
Tesla’s Defrost feature is one of the best and most underrated that the car has in its arsenal. While every car out there has a defrost setting, Tesla’s can be activated through the Smartphone App and is one of the better-performing systems in my opinion.
It has come in handy a lot through the Fall and Winter, helping clear up my windshield more efficiently while also clearing up more of the front glass than other cars I’ve owned.
The test was simple: don’t touch any of the ice or snow with my ice scraper, and let the car do all the work, no matter how long it took. Of course, it would be quicker to just clear the ice off manually, but I really wanted to see how long it would take.
Tesla Model Y heat pump takes on Model S resistive heating in defrosting showdown
Observations
I started this test at around 10:30 a.m. It was still pretty cloudy and cold out, and I knew the latter portion of the test would get some help from the Sun as it was expected to come out around noon, maybe a little bit after.
I cranked it up and set my iPhone up on a tripod, and activated the Time Lapse feature in the Camera settings.
The rest of the test was sitting and waiting.
It didn’t take long to see some difference. In fact, by the 20-minute mark, there was some notable melting of snow and ice along the sides of the windshield near the A Pillar.
However, this test was not one that was “efficient” in any manner; it took about three hours and 40 minutes to get the snow to a point where I would feel comfortable driving out in public. In no way would I do this normally; I simply wanted to see how it would do with a massive accumulation of snow.
It did well, but in the future, I’ll stick to clearing it off manually and using the Defrost setting for clearing up some ice before the gym in the morning.
Check out the video of the test below:
❄️ How long will it take for the Tesla Model Y Performance to defrost and melt ONE FOOT of snow after a blizzard?
Let’s find out: pic.twitter.com/Zmfeveap1x
— TESLARATI (@Teslarati) January 26, 2026
Tesla Robotaxi ride-hailing without a Safety Monitor is proving to be a difficult task, according to some riders who made the journey to Austin to attempt to ride in one of its vehicles that has zero supervision.
Last week, Tesla officially removed Safety Monitors from some — not all — of its Robotaxi vehicles in Austin, Texas, answering skeptics who said the vehicles still needed supervision to operate safely and efficiently.
BREAKING: Tesla launches public Robotaxi rides in Austin with no Safety Monitor
Tesla aimed to remove Safety Monitors before the end of 2025, and it did, but only to company employees. It made the move last week to open the rides to the public, just a couple of weeks late to its original goal, but the accomplishment was impressive, nonetheless.
However, the small number of Robotaxis that are operating without Safety Monitors has proven difficult to hail for a ride. David Moss, who has gained notoriety recently as the person who has traveled over 10,000 miles in his Tesla on Full Self-Driving v14 without any interventions, made it to Austin last week.
He has tried to get a ride in a Safety Monitor-less Robotaxi for the better part of four days, and after 38 attempts, he still has yet to grab one:
Wow just wow!
It’s 8:30PM, 29° out ice storm hailing & Tesla Robotaxi service has turned back on!
Waymo is offline & vast majority of humans are home in the storm
Ride 38 was still supervised but by far most impressive yet pic.twitter.com/1aUnJkcYm8
— David Moss (@DavidMoss) January 25, 2026
Tesla said last week that it was rolling out a controlled test of the Safety Monitor-less Robotaxis. Ashok Elluswamy, who heads the AI program at Tesla, confirmed that the company was “starting with a few unsupervised vehicles mixed in with the broader Robotaxi fleet with Safety Monitors,” and that “the ratio will increase over time.”
This is a good strategy that prioritizes safety and keeps the company’s controlled rollout at the forefront of the Robotaxi rollout.
However, it will be interesting to see how quickly the company can scale these completely monitor-less rides. It has proven to be extremely difficult to get one, but that is understandable considering only a handful of the cars in the entire Austin fleet are operating with no supervision within the vehicle.
Tesla has given its biggest hint that Full Self-Driving in Europe is imminent, as a new feature seems to show that the company is preparing for frequent border crossings.
Tesla owner and influencer BLKMDL3, also known as Zack, recently took his Tesla to the border of California and Mexico at Tijuana, and at the international crossing, Full Self-Driving showed an interesting message: “Upcoming country border — FSD (Supervised) will become unavailable.”
FSD now shows a new message when approaching an international border crossing.
Stayed engaged the whole way as we crossed the border and worked great in Mexico! pic.twitter.com/bDzyLnyq0g
— Zack (@BLKMDL3) January 26, 2026
Due to regulatory approvals, once a Tesla operating on Full Self-Driving enters a new country, it is required to comply with the laws and regulations that are applicable to that territory. Even if legal, it seems Tesla will shut off FSD temporarily, confirming it is in a location where operation is approved.
This is something that will be extremely important in Europe, as crossing borders there is like crossing states in the U.S.; it’s pretty frequent compared to life in America, Canada, and Mexico.
Tesla has been working to get FSD approved in Europe for several years, and it has been getting close to being able to offer it to owners on the continent. However, it is still working through a lot of the red tape that is necessary for European regulators to approve use of the system on their continent.
This feature seems to be one that would be extremely useful in Europe, considering the fact that crossing borders into other countries is much more frequent than here in the U.S., and would cater to an area where approvals would differ.
Tesla has been testing FSD in Spain, France, England, and other European countries, and plans to continue expanding this effort. European owners have been fighting for a very long time to utilize the functionality, but the red tape has been the biggest bottleneck in the process.
Tesla Europe builds momentum with expanding FSD demos and regional launches
Tesla operates Full Self-Driving in the United States, China, Canada, Mexico, Puerto Rico, Australia, New Zealand, and South Korea.
Tesla winter weather test: How long does it take to melt 8 inches of snow?
Tesla Robotaxi ride-hailing without a Safety Monitor proves to be difficult
