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SpaceX readies Falcon 9 Block 5s for bi-coastal launches and landings

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After several months of preparation behind the scenes, SpaceX’s second and third serial Falcon 9 Block 5 rockets are ready for the first launches of the upgraded vehicle from Vandenberg Air Force Base, CA (VAFB) and Cape Canaveral Air Force Station, FL (CCAFS).

On the calendar for 1:50 am EDT/5:50 UTC July 22 and 4:39 am PDT/11:39 UTC July 25, SpaceX launches of Telstar 19V and Iridium NEXT-7 are set to mark the beginning of a new era for the company, where all future missions will fly with Block 5 hardware upgraded for reusability and reliability and attempt recovery almost without fail.

Three Falcon 9 boosters captured in various states of transport and testing over the last six weeks, two of which are B1047 and B1048. (Teslarati/Tesla Motors Club/Reddit/Facebook)

Bursting out of the expendable rocket cocoon

While it may be the case that an odd launch or two require a booster be expended to prevent schedule delays or carry an exceptionally heavy satellite to an exceptionally high orbit, it’s safe to say that such a mission with Block 5 boosters will be an anomaly. Somewhat iffy comments posted on Reddit recently claimed that Falcon Block 5 boosters would be able to easily (and rapidly) hop between roles as side and center boosters for both Falcon 9 and Falcon Heavy. While wild, those claims, in retrospect, make a lot of sense, even if the reality of Block 5 booster interchangeability was a tad exaggerated.

If SpaceX truly wants to end the practice of expending rocket boosters, – and eventually fairings and upper stages, with any luck – the company will truly need to embrace a strategy that’s long been floated by executives like CEO Elon Musk and COO/President Gwynne Shotwell. That strategy dictates that SpaceX routinely use both Falcon 9 and Falcon Heavy as an almost interchangeable and rocket team capable of launching nearly every orbital payload conceivable today, all while remaining in fully or mostly reusable modes of operation.

 

At the moment, educated estimates of Falcon Heavy’s true performance margins with dual booster landings at SpaceX’s Florida landing zones and center core recovery aboard Of Course I Still Love You (OCISLY) suggest that the Block 5 version of Falcon Heavy should be capable of launching every commercial satellite planned or penciled in for launch over the next five years, at a minimum. Finally, while the Falcon family’s fuel choice of high-grade kerosene (RP-1) and liquid oxygen make the rocket far more compact and energy-dense than alternatives, one downside of that choice is a loss of efficiency, although brute-force strength makes FH a competitive beast for all missions beyond Earth orbit (Mars, Venus, Saturn, asteroids, comets, etc).

However, a fully-expendable Block 5 Falcon Heavy seems to be at least 3X as unlikely as an expendable Block 5 Falcon 9. Nevertheless, CEO Elon Musk made it clear that a nominal Falcon Heavy launch where both side boosters were recovered at sea and the center booster expended could accomplish a full ~85-90% of an entirely expendable mission, and for roughly $95m. As such, a combination of reusable Falcon 9s, reusable Falcon Heavys, and ~30%-expendable Falcon Heavys could successfully complete every plausible commercial and non-commercial launch in the world and do so at the lowest cost for the better part of the next five years, at which point the company’s next-gen Big F____ Rocket (BFR) ought to be operational.

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Telstar 19V and Iridium-7

With any luck, SpaceX’s next two launches will be the first huge step in the direction of that one-stop-shop for competitive transportation to orbit. Teslarati photographer Tom Cross will be setting up remote cameras for the Telstar 19V’s Florida liftoff later this evening, while our West Coast fellow and famed Mr Steven-stalker Pauline Acalin will be setting up her own set of remote cameras for VAFB’s Falcon 9 Block 5 debut on Tuesday.

On the East Coast, drone ship OCISLY has already departed Port Canaveral with a duo of support vessels and a dedicated tugboat, while the West Coast’s Just Read The Instructions (JRTI) will likely take leave of the Port of Los Angeles within 24 hours. Those dual, successful (?) rocket landings will hopefully mark the first of many dozens of missions for F9 boosters B1047 and B1048.

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Cheaper launches as a result of reusable rockets may not necessarily increase demand for satellite launches.

The first Block 5 Falcon 9 lifts off on May 4, 2018. Several more are soon to come. (Tom Cross)

Follow us for live updates, peeks behind the scenes, and photos from Teslarati’s East and West Coast photographers.

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Tom CrossTwitter

Pauline Acalin  Twitter

Eric Ralph Twitter

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

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

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Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

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Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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