News
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.
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News
Tesla puts Giga Berlin in Plaid Mode with new massive investment
The facility, Tesla’s first in Europe, opened in 2022 and has become a cornerstone for Model Y production and, increasingly, in-house battery manufacturing. Recent announcements highlight a dual focus on scaling vehicle output and advancing vertical integration through 4680 battery cells.
Tesla is pushing forward with significant upgrades at its Gigafactory Berlin-Brandenburg in Grünheide, Germany, signaling renewed confidence in its European operations despite past market challenges.
The facility, Tesla’s first in Europe, opened in 2022 and has become a cornerstone for Model Y production and, increasingly, in-house battery manufacturing. Recent announcements highlight a dual focus on scaling vehicle output and advancing vertical integration through 4680 battery cells.
In April, plant manager André Thierig announced a 20 percent increase in Model Y production starting in July, following a record Q1 output of more than 61,000 vehicles. To support the ramp-up, Tesla plans to hire approximately 1,000 new employees beginning in May and convert 500 temporary workers to permanent positions.
The move is expected to lift weekly production significantly, addressing rebounding demand in Europe after a challenging 2025.
Today, we announced a $ 250m investment for our Giga Berlin Cell factory. This will enable 18GWh of annual 4680 cell production and create more than 1500 new jobs. Good news during challenging times for the German industry. pic.twitter.com/ou4SWMfWh9
— André Thierig (@AndrThie) May 12, 2026
The expansion builds on earlier progress. In 2025, Tesla secured partial approvals to add roughly 2 million square feet of factory space, raising potential annual vehicle capacity from around 500,000 toward 800,000 units, with longer-term ambitions approaching one million vehicles per year. Logistical improvements, new infrastructure, and battery-related facilities are already underway on company-owned land.
Battery production is the latest major focus. On May 12, Thierig revealed an additional $250 million investment in the on-site cell factory. This more than doubles the planned 4680 battery cell capacity to 18 gigawatt-hours annually—up from the 8 GWh target set in December 2025—while creating over 1,500 new battery-related jobs.
Total cell investments at the site now exceed previous figures, bringing the factory closer to full vertical integration: cells, packs, and vehicles produced under one roof. Tesla describes this as unique in Europe and a step toward stronger supply chain resilience.
The plans come amid regulatory and community hurdles. Earlier expansion proposals faced protests over environmental concerns and water usage, leading to phased approvals beginning in 2024. Tesla has navigated these by emphasizing sustainable practices and economic benefits, including thousands of local jobs in Brandenburg.
With nearly 12,000 employees already on site and production steadily climbing, Gigafactory Berlin is poised for growth. The combined vehicle and battery expansions position the plant as a key hub for Tesla’s European ambitions, potentially making it one of the continent’s largest manufacturing complexes if local support continues.
As EV demand recovers, these investments underscore Tesla’s commitment to scaling efficiently in Germany while addressing regional supply chain needs.
News
Honda gives up on all-EV future: ‘Not realistic’
Mibe believes the demand for its gas vehicles is certainly strong enough and has changed “beyond expectations.” As many drivers went for EVs a few years back, hybrids are becoming more popular for consumers as they offer the best of both worlds.
Honda has given up on a previous plan to completely changeover to EVs by 2040, a new report states. The company’s CEO, Toshihiro Mibe, said that the idea is “not realistic.”
Mibe believes the demand for its gas vehicles is certainly strong enough and has changed “beyond expectations.” As many drivers went for EVs a few years back, hybrids are becoming more popular for consumers as they offer the best of both worlds.
Mibe said (via Motor1):
“Because of the uncertainty in the business environment and also the customer demand, is changing beyond our expectation and, therefore, we have judged that it’ll be difficult to achieve. That ratio [100-percent electric in 2040] is not realistic as of now. We have withdrawn this target.”
Instead of going all-electric, Honda still wants to oblige by its hopes to be net carbon neutral by 2050. It will do this by focusing on those popular hybrid powertrains, planning to launch 15 of them by March 2030.
Honda will invest 4.4 trillion yen, or almost $28 billion, to build hybrid powertrains built around four and six-cylinder gas engines.
There are so many companies abandoning their all-electric ambitions or even slowing their roll on building them so quickly. Ford, General Motors, Mercedes, and Nissan have all retreated from aggressive EV targets by either cancelling, delaying, or pausing the development of electric models.
Hyundai’s 2030 targets rely on mixed offerings of electric, hybrid & hydrogen vehicles
Early-decade pledges from multiple brands proved overly ambitious as infrastructure lags, battery costs remain high in some markets, and many buyers prefer hybrids for their convenience and range. Toyota has long championed hybrids, while others have quietly extended internal-combustion timelines.
For Honda—historically known for reliable gasoline engines—this shift leverages its core strengths while buying time to refine electric technology. Whether the hybrid-heavy strategy will protect market share in an increasingly competitive landscape remains to be seen, but one thing is clear: the gas engine is far from dead at Honda, unfortunately.
Elon Musk
Delta Airlines rejects Starlink, and the reason will probably shock you
In a pointed exchange on X, Elon Musk defended SpaceX’s uncompromising approach to Starlink’s in-flight internet service, explaining why Delta Air Lines walked away from a deal.
SpaceX frontman Elon Musk explained on Wednesday why commercial airline Delta got cold feet over offering Starlink for stable internet on its flights — and the reason will probably shock you.
In a pointed exchange on X, Elon Musk defended SpaceX’s uncompromising approach to Starlink’s in-flight internet service, explaining why Delta Air Lines walked away from a deal.
Delta rejected Starlink because it insisted on routing all connectivity through its branded “Delta Sync” portal rather than allowing a simple Starlink experience.
Instead, the airline partnered with Amazon’s Project Kuiper—rebranded as Amazon Leo—for high-speed Wi-Fi on up to 500 aircraft, with rollout targeted for 2028. At the time of the announcement, Kuiper had roughly 300 satellites in orbit, while Starlink operated more than 10,400.
The use of the “Delta Sync” portal would not work for SpaceX, as Musk went on to say that:
“SpaceX requires that there be no annoying ‘portal’ to use Starlink. Starlink WiFi must just work effortlessly every time, as though you were at home. Delta wanted to make it painful, difficult and expensive for their customers. Hard to see how that is a winning strategy.”
Musk doubled down in a follow-up post:
“Yes, SpaceX deliberately accepted lower revenue deals with airlines in exchange for making Starlink super easy to use and available to all passengers.”
Not exactly. SpaceX requires that there be no annoying “portal” to use Starlink.
Starlink WiFi must just work effortlessly every time, as though you were at home.
Delta wanted to make it painful, difficult and expensive for their customers. Hard to see how that is a winning…
— Elon Musk (@elonmusk) May 13, 2026
SpaceX has structured its airline agreements to prioritize zero-friction access—no captive portals, no SkyMiles logins, no paywalls or ads blocking basic connectivity.
While this means forgoing higher-margin deals that would let carriers monetize the service more aggressively, it ensures Starlink feels like home broadband at 35,000 feet. Passengers on partner airlines such as United, Qatar Airways, and Air France have already praised the service for enabling seamless video calls, streaming, and work mid-flight without interruptions.
Delta’s choice reflects a different philosophy. By keeping Wi-Fi behind its Delta Sync ecosystem, the airline aims to drive loyalty program engagement and control the digital passenger journey. Yet, critics argue this short-term control comes at the expense of immediate competitiveness.
Airlines already installing Starlink are pulling ahead in customer satisfaction surveys, while Delta passengers face years of reliance on slower, legacy systems until Leo launches.
SpaceX’s decision to trade revenue for simplicity will pay off in the longer term, as Starlink is already positioning itself as the default high-speed option for carriers that value passenger satisfaction over incremental fees.
Musk’s focus on creating not only a great service but also a reasonable user experience highlights SpaceX’s prowess with Starlink as it continues to expand across new partners and regions.
Tesla puts Giga Berlin in Plaid Mode with new massive investment
Honda gives up on all-EV future: ‘Not realistic’
