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SpaceX Falcon 9 rocket lands for the last time ahead of risky in-flight abort test

Falcon 9 B1048 returned to Port Canaveral on Feb. 24 after the rocket's third successful launch and landing. (Tom Cross)

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8 years ago

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SpaceX’s latest successful launch and landing has wrapped up with Israeli Moon lander Beresheet on its way to Earth’s neighbor, Indonesian communications satellite PSN-6 headed to its final orbit, and the second thrice-flown Falcon 9 Block 5 booster safely returned to Port Canaveral aboard drone ship Of Course I Still Love You (OCISLY).

Known as Falcon 9 B1048, its third successful landing and recovery will almost certainly be this booster’s last after its fourth launch was officially assigned to a critical Crew Dragon launch abort test, one that the booster is very unlikely to survive. According to SpaceX CEO Elon Musk, that test could occur as early as April and will push the first flight-proven Crew Dragon space capsule to its limits.

https://twitter.com/_TomCross_/status/1099688043009753088

After weathering what Musk also described as the toughest reentry and heating conditions yet experience by a Falcon 9 booster meant for recovery, Falcon 9 B1048 landing (almost) flawlessly aboard drone ship OCISLY, stationed roughly 700 km (430 mi) off the Florida coast. Hinted at by the booster’s very slight lean on the recovery vessel’s deck, B1048 most likely cut thrust (or ran out of fuel) just before the optimal stop point, causing the rocket to fall a few unintended feet onto OCISLY and eat into part of the aluminum honeycomb ‘crush-core’ present on all Falcon landing legs.

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In essence, that crushable aluminum acts as a very rough form of emergency suspension meant to minimize potential damage to the fragile structure of Falcon booster propellant tanks at the cost of its landing legs. In the case of B1048’s third landing, the lean appears to be no more than a few degrees – scarcely out of the ordinary, at least relative to past leaning boosters. Most notably, Falcon 9 B1023 experienced a similar anomaly and a far worse lean after its first landing, an experience that did not apparently impact its ability to launch for the second time as a side booster for Falcon Heavy’s inaugural launch.

 

B1048’s slight departure from a perfect trajectory should thus pose no problem for in-place plans for the rocket’s fourth (and likely final) launch. Known as Crew Dragon’s in-flight abort (IFA) test, SpaceX specifically requested the inclusion of a second abort test (above and beyond NASA’s testing requirements) to fully verify that astronauts could be pulled to safety at any point during launch. In 2015, the company completed a pad abort test of Crew Dragon, demonstrating that the spacecraft could escape from a failing rocket while static on the launch pad. The in-flight abort is precisely what it sounds like: a demonstration that Crew Dragon can safely escape a failing rocket while in flight. More than simply being in flight, the goal is to demonstrate a successful abort at the point of peak aerodynamic stress of Falcon 9 and Dragon, known as Max Q.

For Cargo Dragon launches, Falcon 9 has typically averaged dynamic forces of about 25 kPa (~4 psi), roughly equivalent to 2.5 tons of force per square meter. During launch, either the payload fairing or Cargo/Crew Dragon are subjected directly to those forces, often requiring a significant period of lower throttle to mitigate the forces those sensitive assemblies experience. Given that Crew Dragon’s abort scenario accelerates the capsule and trunk from a relative speed of zero to nearly 350 mph (150 m/s) in five seconds, the dynamic forces (i.e. mechanical loads and heating) the spacecraft is experiencing could jump 50% or more almost instantaneously.

 

After Crew Dragon aborts, the Falcon 9 stack – featuring B1048 and a full-fidelity upper stage with a mass simulator in place of its MVac engine – will be instantaneously exposed to those same dynamic forces, experientially equivalent to bellyflopping from an Olympic-height diving platform. The upper stage may actually be better off than the booster thanks to the generally smooth dome at its stern, whereas Falcon 9’s booster would have its interstage – a deep, open cylinder – exposed to the same airflow if or when the upper stage is torn away. At the point of abort, Falcon 9 will most likely be in the process of shutting down its Merlin 1D engines, effectively removing the booster’s control authority and leaving it at the mercy of the atmosphere. SpaceX’s CRS-7 Cargo Dragon failure (caused by the second stage losing structural integrity mid-flight) is actually a decent representation of what is likely to happen to B1048 and its upper stage.

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Given the potential destructive power B1048 will face, not to mention the fact that the booster will likely not have grid fins or landing legs installed, today’s recovery will probably be the last time the rocket returns to port and prepares for another launch. Explicitly dependent upon the refurbishment of DM-1’s Crew Dragon capsule, SpaceX’s in-flight abort is not expected to occur until June 2019, although Musk has indicated that the aspirational target is to perform the test as early as April, perhaps less than 60 days after the capsule is scheduled to land in the Atlantic Ocean.

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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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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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3 days ago

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September 18, 2026

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

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Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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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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4 days ago

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September 18, 2026

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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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Investor's Corner

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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5 days ago

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September 17, 2026

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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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