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SpaceX's workhorse rocket is almost halfway to reaching ambitious reusability goals

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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.

SpaceX’s twin fairing recovery ships are effectively 50% of the way to enabling full Falcon fairing reusability. (Richard Angle)
SpaceX’s upgraded Falcon Block 5 boosters, meanwhile, are rapidly approaching the halfway point to a major reusability milestone. (Richard Angle)

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.

Ms. Chief has yet to make her first fairing ‘catch’ but the ship still managed to safely retrieve one of Starlink V1 L3’s fairing halves from the ocean. (Richard Angle)
Ms. Tree (formerly Mr. Steven), however, nailed her third fairing catch ever, following successes in June and August 2019. (Richard Angle)

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.

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Falcon 9 booster B1048. (Pauline Acalin, SpaceX, Tom Cross, Richard Angle – Teslarati)

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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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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Tesla Cybercab and Robotaxi’s real advantage won’t be the ride service

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Concept art of a Tesla Cybercab in Las Vegas Strip as rendered via Grok

For a century, the car has asked the same thing of its owner, which is basically to pay attention. Even the best ride-hailing app like Uber or Lyft only moved the problem into someone else’s hands. You stopped driving, but you still sat in a stranger’s car, while half listening, and wondering whether to take a phone call in the car without being rude. The Cybercab has no wheel, no pedals and no driver. With Grok @bot now live inside it, it becomes something else entirely, and I think that matters more than the fleet count that everyone is tracking.

Grok @bot is an agent, not a voice assistant. A rider signs in once, and from then on can say what they need and watch it happen. Order dinner from a favorite restaurant. Fill the grocery cart. Move money, answer email, adjust a calendar, push a work project forward. Tesla engineer Yun-Ta Tsai confirmed it is enabled across every Cybercab and the rest of the Model Y fleet, and Tesla’s own pitch is that Full Self-Driving handles the commute while Grok handles the errands.

Think about what that does to a thirty minute ride. Uber sells you a trip, while Waymo sells you the same trip in a more private setting. Tesla is selling the thirty minutes themselves, returned to you with an assistant attached. Errands that used to eat a Saturday get done between pickup and drop off. The ride stops being dead time between two places and becomes a place of its own.

Tesla integrates Grok Bot into its vehicles for the ultimate personal assistant

Best of all, your Bots follow you into any Cybercab, and presumably your own Tesla, then logs you out automatically when you step out. Anyone can bolt a chatbot onto a screen, but much harder to own the vehicle, the autonomy stack and the assistant at once. It also quietly ties SpaceX’s Super Intelligence business to Tesla’s fleet, after Tesla converted its xAI stake into SpaceX equity. The relationship between those two companies is getting harder to describe as separate.

This is also where the hard questions start, because an agent that can spend your money in a vehicle other people also ride in needs some answers. How does it handle a voice it shouldn’t trust? What gets recorded, who can see it, and for how long? What happens when a rider leaves halfway through a task?

If Tesla gets those answers right, the scoreboard changes. We have been counting Cybercabs and wait times. The more telling number may be what riders accomplish per trip. That is data almost no one else will ever have, and it is the real reason to watch Grok @bot.

What do you think? Leave me a comment.

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Why Elon Musk’s target date for buying an Optimus robot is harder than it sounds

Musk says China’s magnet export ban cost Optimus months, and robot hands remain shockingly hard.

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Concept rendering of Tesla Optimus in mass production

Elon Musk says China’s export curbs on magnets used in electric motors set back Tesla’s Optimus program by two to three months, and that the robot’s hands remain the hardest part of the project. He made the comments Saturday during a live interview with Tesla Owners Silicon Valley at the X Takeover event at Giga Texas, in front of roughly 2,000 attendees. The Optimus discussion begins around the 49 minute mark of the stream.

On the hands, Musk was blunt and noted that a general purpose humanoid needs fine motor skills that are “incredibly difficult to get right. Shockingly difficult,” he said in the interview. He pointed to a problem he says no one has demonstrated yet: “One of the hardest things also generally is to do precision and force at the same time,” such as driving a small self tapping screw into wood. Touch sensors add another layer, since it is “actually kind of hard to get touch sensors that elastically deform and can handle high cycle life and it won’t just break after a few thousand cycles.”

He also took aim at rival robot videos. “Any complicated looking robot demo, it’s a canned demo. It’s not real,” Musk said, adding that real AI means showing a robot something it has never seen and watching it still cope, the way FSD handles a city it has never driven.

Musk expects the Optimus ramp to be slower than a new vehicle production ramp. “The initial part of that S curve of production ramp is going to be very slow at the beginning,” Musk said, partly because “unlike cars, there’s no pre existing supply chain for robot stuff.” That echoes his July reply on X that Optimus production “will be extremely slow at first, as everything is new.”

The magnet disclosure puts a number on a problem Musk first raised in 2025. He said China “prevented the export of magnets for use in electric motors” and that it “set back the Optimus program by like two or three months.” Then he added: “We had robots with no arms.” Tesla’s fix is to bring the supply chain home. “You’ve got to be able to make all the parts domestically,” he said. Teslarati reported in April 2025 that Musk tied the issue to permanent magnets in the arm actuators, where motors have to be as small as possible.

Tesla Optimus V3 hand and arm details revealed in new patents

Production is moving regardless, with a reported internal goal of more than 1,000 a week by the end of 2026. Teslarati recently covered how Tesla is certifying supply partners in China for Optimus parts, while the company’s hand design has been the subject of new patent filings.

Musk has said he wants Optimus available to the public by late 2027, though Tesla has not confirmed that date or published updated production figures.

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Investor's Corner

Elon Musk drops a Thanksgiving hint about Starship’s biggest test yet

Elon Musk says Starship Flight 15 will try to catch the ship itself, a first.

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Elon Musk says SpaceX’s next Starship flight will try something nobody has done before, by catching the ship itself. Speaking to roughly 2,000 people at the X Takeover event at Giga Texas on Saturday, Musk said Flight 15 is about four to six weeks away and “probably launches a little bit before Thanksgiving, is my guess.”

That is a slip from earlier reporting, which had pointed to a launch as early as October 19. Musk explained why the date keeps moving. “We’re making a bunch of improvements to the rocket between every flight,” he said, adding that there are often hundreds, sometimes thousands, of small changes. This time the list is short, “but some of them take a fair bit of work and we’ve got to go inside the tank to make some of these changes.”

“We’re going to try to catch the ship, which is a super big deal,” Musk said. “If we do so, that’ll be the first time that there’s been full recovery of an orbital class rocket.” SpaceX has already caught the Super Heavy booster with the tower’s mechanical arms, and has talked about catching the ship since late 2025, but the upper stage has never been caught.

Musk also laid out what comes after. “The next big milestone would be to refly both the booster and the ship,” he said, describing a Flight 16 where “all parts of an orbital rocket are reflown.”

The reason SpaceX wants this comes down to cost and cadence. Every Starship ship so far has ended its flight in the ocean, and SpaceX expects most of those water landings to end in fireballs. A ship that returns to Starbase intact can be inspected and flown again. SpaceX’s IPO filing, says Starship V3 is designed to deliver 100 metric tons to orbit in a fully reusable configuration, that SpaceX aims to cut the cost to reach orbit by 99% or more versus the historical average, and that tower catches should allow “multiple launches per day.”

The payoff goes beyond cheaper launches. The next generation Starlink V3 satellites are too large for Falcon 9 and can only fly on Starship, which can carry up to 60 per flight. Flight 14 on September 28 deployed the first 26 of them after Starship reached orbit despite an early engine shutdown, as Teslarati reported. Musk blamed engine computer software, and said the heat shield “was extremely robust,” which he claimed in August had solved Starship’s biggest challenge.

NASA’s Moon plans depend on the same capability. NASA’s inspector general has described a lander mission that needs a propellant depot in low Earth orbit and more than 10 tanker flights, with SpaceX targeting one tanker launch every six days. That schedule only works if ships and boosters come back fast and fly again. Also, ship to ship propellant transfer has not been attempted yet.

One interesting hurdle yet to be explored is bringing the ship back to the launch site, with reentry over land, which will undoubtedly come with a lot of aviation safety reviews.

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