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SpaceX's workhorse rocket is almost halfway to reaching ambitious reusability goals
Thanks to a recent cluster of major milestones, SpaceX’s family of Falcon 9 and Heavy rockets are rapidly nearing the halfway point along the path to several ambitious goals for booster and fairing reusability.
Back in the early 2010s, SpaceX’s CEO Elon Musk’s original dream was to make Falcon 9 and Falcon Heavy 100% reusable, meaning that the company would need to find ways to reliably recover boosters (first stages), payload fairings (or Dragon spacecraft), and the rocket’s upper (second) stages. The concept of Falcon 9 second stage reuse actually survived all the way into 2018 before Musk ultimately conceded defeat, accepting that Falcon 9 and Heavy simply didn’t offer the performance necessary to make full reusability a worthwhile investment. The concept, however, still lives on in SpaceX’s next-generation Starship launch vehicle.
This does mean Falcon rockets will never be fully reusable, but it’s still up to SpaceX to decide how far they’ll push the envelope with the rockets’ existing reusable hardware. At the moment, it appears that a vast majority of Falcon rockets will be able to be routinely recovered and reused, capitalizing on the fact that Falcon 9 and Falcon Heavy boosters already represent some 50-75% of the cost of building each two-stage rocket. While Falcon upper stages and Dragon trunks will never be reused, both booster and payload fairing reuse are rapidly approaching their own unique halfway points on the path to ambitious reusability targets.


Shortly after SpaceX’s January 29th Starlink V1 L3 launch, carrying the third batch of 60 upgraded v1.0 satellites to orbit, twin fairing recovery ships GO Ms. Tree (formerly Mr. Steven) and Ms. Chief teamed up for their second-ever simultaneous fairing catch attempt. Ms. Chief – only active since November 2019 – reportedly just barely missed her first successful catch, while Ms. Tree managed to snag one of the Falcon 9 fairing halves in her massive net – the ship’s third successful catch.
Worth an estimated $3M per half according to CEO Elon Musk, Falcon 9’s payload fairing represents approximately 10% of the rocket’s total manufacturing cost. Made out of a carbon fiber and aluminum honeycomb composite material, fairings also also takes a disproportionate amount of time and space to produce – primarily due to their large size (a school bus could comfortably fit inside a fairing) and the need for commensurately large curing ovens. That composite honeycomb structure also makes it relatively easy for Falcon payload fairings to suffer from corrosion when dunked in seawater, leading SpaceX to the seemingly bizarre solution of installing giant arms and nets on ships.


Catching fairings has proven to be incredibly unforgiving, however, and SpaceX has simultaneously worked to make its Falcon fairings much more waterproof (and thus resistant to corrosion) while keeping them as light as possible. In fact, SpaceX’s first fairing reuse occurred less than three months ago and used two halves that previously landed in the Atlantic Ocean, demonstrating that difficulties reliably catching fairings will not stand in the way of reuse.
Ms. Chief missed her January 29th catch attempt, she still managed to fish her fairing half out of the ocean, while Ms. Tree’s successfully-caught half means that SpaceX ultimately recovered the full Starlink V1 L3 fairing. With a little luck, that recovered fairing will launch again in the near future.
Five for 5
Simultaneously, SpaceX is making excellent progress along the path to airliner-like rocket reusability. In November 2019, on the same Starlink mission that debuted flight-proven fairings, Falcon 9 booster B1048 became the first SpaceX rocket to launch (and land) four times. Less than two months later, Falcon 9 B1049 doubled down on that reusability milestone, becoming the second booster to launch and land four times, followed by Falcon 9 B1046 just 12 days later. Falcon 9 B1046 was (intentionally) destroyed after its fourth launch, precluding a fourth landing attempt, but it emphasizes just how confident SpaceX is in Falcon 9’s Block 5 upgrade.

Designed to allow each Falcon 9 and Heavy booster to perform a minimum of 10 launches and landings, the Block 5 upgrade is potentially just a few weeks away from reaching the halfway point along the path to that ambitious reusability design goal. Speaking at the NASA Kennedy Space Center earlier this month, a SpaceX engineer recently revealed that a Falcon 9 booster would conduct its fifth launch in support of a Starlink mission (either Starlink V1 L4 or L5) scheduled no earlier than (NET) mid-to-late February.
Pictured above, Falcon 9 booster B1048 – the first to launch four times – is the likeliest candidate for the first fifth flight of a SpaceX rocket. If the booster’s reuse goes as planned, it’s safe to say that Falcon 9 B1049.4 will follow closely on the heels of its predecessor with its own fifth-flight milestone. All things considered, SpaceX’s workhorse rocket is rapidly approaching the zenith of its theoretically-achievable reusability.
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Elon Musk
Tesla shows what Roadster drivers will see on screen before thruster activation
Tesla’s Roadster video reveals a fighter jet inspired cockpit with a 5,500 PSI thruster gauge.
Tesla has given future owners their clearest look yet at the cockpit of its next generation Roadster. In a 34 second video posted to X on Friday afternoon, the company walked through the car’s touchscreen with a caption: “Inspired by fighter jet cockpits, Roadster’s interface was designed around the pilot.”
The clip opens on a black screen with red graphics and a 3D wireframe of the car, which sits beside the Roadster’s squared off yoke. Tapping parts of the model brings up controls for the rear wing, including low drag and high downforce positions, along with a charging page with a charge limit bar and a small music player. A row of tabs along the bottom reads Home, Vehicle, Listen, Climate and Navigate.
Most of the video is spent in Track Mode. The dashboard shows a live circuit map, a list of session lap times, brake and motor temperatures, and pressure and temperature readouts for each tire. A setup page lets the driver pick Auto, Low Drag, High Downforce or Custom aero modes, adjust aero balance and brake balance, and switch stability and traction control off. Along the bottom, a status bar reads “Thruster · 5,500 PSI” next to a “Boost Ready” indicator.
That gauge ties the software to the hardware Tesla showed off near Waco, Texas on October 15. The Thrust and Rocket versions use cold gas thrusters fed by carbon overwrapped pressure vessels, and Tesla lists 0 to 60 mph times of under 0.9 seconds and under 0.59 seconds for them, as Teslarati detailed in its breakdown of the three Roadster configurations. The base Performance car relies on a fan and ground sealing system for grip, and the aero settings on screen match the active wings and suction setup covered in our look at how the Roadster generates downforce.
The Roadster layout is a departure from the rest of Tesla’s lineup. Instead of a map centered screen, the Roadster puts the car itself at the center of the home page, and Tesla’s Roadster page lists two smaller forward displays alongside the main touchscreen. Tesla has not said whether any of the Track Mode telemetry will make its way to the Model 3 Performance or other vehicles.
The interface could still change before deliveries. Elon Musk said at the event that Roadster production will begin in 2028, and Tesla says the flagship Rocket version is not approved for public road use. Reservations are open with a $50,000 payment, while Thrust is listed as a limited release and Rocket is invite only.
Those who want to see the car in person will get their first chance this weekend. The Roadster goes on display in the lobby of the Petersen Automotive Museum in Los Angeles from October 24 to 27, according to Sawyer Merritt, the first time the public will be able to view it up close.
Elon Musk
Tesla reveals Optimus Academy, where robots teach themselves
Tesla has begun building production quality Optimus robots in Fremont and revealed its training plan.
Tesla has started building Optimus on the high volume line it set up inside its Fremont factory, and the company says the robots coming off it are the first that meet the bar for a real product. “The bots coming off this line are the first production-quality bots that we have manufactured,” Tesla wrote in its third quarter shareholder letter, adding that it has “proven that the current manufacturing process for Optimus is suitable for a commercial product.”
The line sits in space that built the Model S and Model X until this spring. Tesla cleared the old vehicle line in 46 days, as Teslarati reported in July, to make room for robot production sized for one million units a year. On Wednesday’s earnings call, Elon Musk said most of the equipment for that capacity is already in Fremont, with output set to climb toward roughly 20,000 robots a week as the line ramps.
Musk described the ramp as a classic S curve. “The growth of Optimus is an S curve, but the initial curve is a shallow slope,” he said. The team is now refining the robot’s AI, electromechanical design, reliability and service life, and Musk expects that work to be finished by the end of next year, when Tesla plans to start delivering Optimus to outside companies for dangerous, repetitive and around the clock jobs.
The most interesting part of the call was how Tesla plans to teach the robots. Its cars send real driving data back to the AI team from millions of vehicles, but Optimus has no fleet like that yet. “A big difference with Optimus versus the cars is we don’t have this vast fleet of cars from which we can gather training data,” Musk said. Tesla’s answer is an Optimus Academy, where 10,000 to 20,000 robots will practice a wide range of tasks and feed what they learn into the next version of the model. Every unit off the Fremont line becomes a source of that training data.
Smarter hardware is on the way too. Tesla plans to put its AI5 chip into Optimus next year, and Musk said a new Optimus video should arrive within one or two months showing the robot completing tasks driven by AI rather than preprogrammed motions. He took aim at rival humanoid demos that only run scripted routines, saying those would not hold up in the real world.
The supply chain is lining up behind the program. In September, Tesla certified Tuopu, Joyson and Sanhua as mass production partners for Optimus components. A far larger Optimus factory is also rising at Giga Texas, where drone footage from Joe Tegtmeyer showed the steel frame nearing completion, and Musk has pegged that plant’s long term target at 10 million robots a year.
Tesla executives also said Optimus production costs are trending toward the expected manufacturing cost of Cybercab, a sign the robot is being engineered for volume from the start. The hands remain the toughest piece of the design, a point Musk also made at the X Takeover event earlier this month, as Teslarati covered at the time, and that is where much of the current engineering effort is focused.
Elon Musk
The Starship moon landing number NASA and Elon Musk can’t agree on
Musk disputes NASA estimate of 22 Starship launches for Moon landing, predicting 6 to 8.
Elon Musk is disputing a new NASA safety panel estimate of how many Starship launches it will take to put astronauts on the Moon, saying the real number will be less than half the panel’s figure.
On Thursday, NASA’s Aerospace Safety Advisory Panel held its quarterly public meeting. Panel member Charlie Precourt, a former NASA astronaut, flagged the fueling process for SpaceX’s lunar lander as a major risk for Artemis IV, the mission planned to land a crew on the Moon in 2028. “We need to keep our eyes on numerous required fuelings for the lander,” Precourt said, according to Ars Technica. “I think the last estimate is around 22 flights.”
Ars Technica’s Eric Berger posted the comment on X, and Musk replied. “That’s way too high,” Musk wrote. “Actual number will be more like 6 to 8.”
The disagreement comes down to a basic problem with sending a ship as large as Starship to the Moon. Starship burns nearly all of its propellant just reaching Earth orbit, so it cannot continue on to the Moon without stopping for a refill. SpaceX’s answer is a gas station in space. First, a Starship that works as a storage tank, called a depot, is launched into orbit. Then a series of tanker Starships launch one at a time, dock with the depot and pump their leftover propellant into it. Once the depot is full, the lunar lander version of Starship launches, docks, fills up and heads for the Moon.
Every tanker trip is its own full rocket launch, which is why the count matters. More launches mean more time, more cost and more chances for something to go wrong before astronauts ever leave Earth. Berger estimated that even if SpaceX reaches twice weekly Starship launches by the end of 2027, filling a depot at the panel’s number would still take roughly three months.
How many tankers are needed depends mostly on how much propellant each one can carry to orbit and how much is lost along the way. Starship’s fuel and oxygen are stored at extremely cold temperatures, and some of it slowly boils off while waiting in orbit. More is lost in each transfer. NASA appears to be working from what Starship can lift today, while Musk’s range assumes a more capable rocket.
Musk has pushed back on higher counts before. In 2021, after a government document suggested 16 launches, he called that “extremely unlikely” and said eight tankers would be the most required.
Much of the answer depends on hardware SpaceX has not finished flying. As Teslarati noted earlier this year, the company plans to carry out the refueling process with its upgraded V3 Starship, and Precourt described Artemis IV as carrying “a large number of firsts.” He also praised NASA Administrator Jared Isaacman’s team for working to clear obstacles for both SpaceX and Blue Origin, whose Blue Moon lander does not rely on orbital refueling for its first mission.