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SpaceX ship headed 1000 kilometers out to sea for expendable Falcon 9 launch

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Update: SpaceX has called off Monday’s launch attempt for what appears to be technical reasons and will try again on Tuesday, November 22nd.

A SpaceX recovery ship is headed more than a thousand kilometers downrange to support the second expendable Falcon 9 rocket launch in nine days.

No earlier than (NET) 9:57 pm EST (02:57 UTC) on Monday, November 21st, a Falcon 9 rocket is scheduled to lift off from SpaceX’s Cape Canaveral Space Force Station (CCSFS) LC-40 pad carrying the Eutelsat 10B geostationary communications satellite. For unknown reasons, the French communications provider paid extra to get as much performance as possible out of Falcon 9, requiring SpaceX to expend the rocket’s booster instead of attempting to land and reuse it.

The mission will be Eutelsat’s third Falcon 9 launch in less than three weeks and will wrap up a trio of launch contracts the company secretly signed with SpaceX to move satellites off of competitor Ariane Group’s unavailable Ariane 5 and delayed Ariane 6 rockets. In a rare coincidence, Eutelsat 10B will also be SpaceX’s second expendable Falcon 9 launch in a row and the third Falcon launch to expend a booster this month. But like those two other missions, not all of the Falcon rocket tasked with launching Eutelsat 10B will be lost.

While SpaceX’s spectacular Falcon booster recovery and reuse usually takes center stage, the company has also managed to become the first entity in the world to successfully recover and reuse the deployable nosecone (fairing) that protects satellite payloads during launch. More importantly, Falcon fairing recovery and reuse have quietly become routine, reliable, and even accepted by an increasing number of paying customers. Out of 52 Falcon rockets launched in 2022, a minimum of 40 used at least one reused fairing half, and four of those 52 launches carried Dragon spacecraft (no fairing).

By all appearances, the performance penalty added by the extra mass of the hardware needed to recover Falcon fairings is also so minor that SpaceX can still recover fairings even when a given mission requires the company to expend a Falcon booster. That’s become especially clear within the last few weeks.

On November 1st, a SpaceX Falcon Heavy rocket lifted off for the fourth time ever, and intentionally expended one of its three first-stage boosters for the first time. Despite the booster’s disposal and record-smashing speed at main engine cut-off (MECO; 4 km/s or 8900 mph), SpaceX still managed to recover both of Falcon Heavy’s hypersonic fairing halves after they reentered Earth’s atmosphere and splashed down in the Atlantic Ocean almost 1500 kilometers (~930 mi) downrange. Eleven days later, SpaceX expended a Falcon 9 rocket to launch two Intelsat communications satellites. Once again, both fairing halves were recovered – this time around 960 kilometers (598 mi) downrange.

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Aiming for a region 1015 kilometers (630 mi) downrange, Eutelsat 10B’s fairing halves have the potential to travel further than any other piece of Falcon hardware before a successful recovery.

Compared to booster recovery, fairing recovery is more of a convenience than a necessity, and was pursued partially because it allowed SpaceX to avoid dramatically expanding its fairing production facilities in Hawthorne, California. Each Falcon Block 5 booster reuse likely saves SpaceX tens of millions of dollars, while CEO Elon Musk once implied that a standard Falcon fairing half costs about $3 million to build.* But given that SpaceX is now routinely reusing fairing halves five, six, or even seven times in two to three years, it’s likely that each fairing recovery still saves SpaceX a few million dollars.

*Musk specifically said that the fairing represents about 10% of the cost of a new Falcon 9 rocket. That cost could be higher than SpaceX’s Falcon 9 launch price, which was $62 million in 2017 and has grown to $67 million in 2022.

A Falcon 9 fairing half floats on the Pacific in 2018. SpaceX ultimately abandoned attempts to catch fairings out of mid-air and instead improved waterproofing to the point that halves can be reused after landing directly on the ocean surface. (SpaceX)

As was the case with SpaceX’s most recent launch, which made Falcon 9 booster B1051’s 14th mission its last, the company has assigned another old Falcon 9 booster to launch Eutelsat 10B. The mission will be Falcon 9 B1049’s 10th and final launch, ending the career of the oldest booster in SpaceX’s fleet. B1049 debuted more than four years ago in September 2018. Older Falcon Block 5 boosters are generally more finicky and high-maintenance, which partially explains why B1049 will retire after completing four fewer launches than B1051, a booster that’s six months younger.

Tune in below to watch SpaceX expend a Falcon booster for the third time in one month – an unfamiliar ‘first’ for a company famous for landing rockets.

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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Cybertruck

Tesla Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

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

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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SpaceX has solved Starship’s biggest challenge, Elon Musk says

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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