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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
Elon Musk to file lawsuit against former US Rep Jamaal Bowman: “I’ve had enough”
Bowman called the Tesla CEO a “Nazi” and a “thief” during a segment on CNN.
Elon Musk has announced that he is filing a lawsuit against former United States Representative Jamaal Bowman over his recent comments in a CNN segment.
Musk shared his legal intentions in a post on social media platform X.
Bowman’s Comments
During an appearance on CNN, Bowman, who made news in 2023 by triggering a fire alarm while Congress was in session, strongly criticized Elon Musk. Unlike other Musk critics, Bowman went straight for the jugular, calling the CEO a “Nazi” and a “thief.” Bowman’s comments received polarizing reactions in social media, with some users stating that such words could be used to sue for defamation.
“The American people do not trust Elon Musk. And Elon Musk is incompetent in his position. And how do we know? Because they fired tens of thousands of people, it was challenged in court, the court said people have to go back, and now the people are coming back. He’s incompetent, he’s a thief, he’s a Nazi, and people don’t trust him,” Bowman said.
“I’ve Had Enough”
In a comment to a video of Bowman’s CNN segment that was shared on X, Musk stated that the former Democratic Congressman’s words have crossed a line. “I’ve had enough. Lawsuit inbound,” Musk wrote in a post on X. Musk’s post received some support from X users, several of whom noted that it’s high time the CEO fought back against the vitriol that is consistently thrown his way.
Musk has been on the receiving end of protests from critics who oppose his work with U.S. President Donald Trump and the Department of Government Efficiency (DOGE). Opposition against Musk has spilled over to Tesla, resulting in stores being shot, firebombed by Molotov cocktails, vandalized, and vehicles and Superchargers being subjected to arson. Even regular Tesla owners have reported a growing wave of vandalism incidents.
News
Tesla aiming to produce first “legion” of Optimus robots this 2025
Tesla is aiming to start the production of Optimus this year, and its first run will be no joke.
Tesla’s Q1 2025 All-Hands meeting saw CEO Elon Musk share a key update about the company’s most ambitious product yet — Optimus. As per Musk, Tesla is aiming to start the production of Optimus this year, and its first run will be no joke.
Tesla Optimus’ Quick Evolution
Tesla initially announced Optimus during its AI Day event in 2021. At the time, Tesla only had a mockup of the robot and a literal person in a suit to demonstrate what Optimus could look like. By 2022, Tesla had a working prototype of the robot. Optimus’ progress has been rapid since then, with several dozens of the humanoid robots interacting with attendees at the Cybercab’s unveiling last October.
Optimus’ Potential
During the recent All-Hands meeting, Elon Musk reiterated the idea that Optimus could very well be the biggest product of all time, likely being ten times larger than the next-biggest product. Musk also shared an update about Optimus’ production, stating that the first humanoid robot has been manufactured at the Fremont Factory.
A Legion for 2025
When discussing Optimus’ ramp, Musk clarified that Tesla is internally aiming for enough parts to produce 10,000 to 12,000 Optimus robots this year. However, since Optimus is a completely different product, even half of 10,000 units would be a huge victory for Tesla. Tesla also plans to ramp Optimus to a notable degree in 2026, with the company aiming for 50,000 units, or 10 “legions” of humanoid robots, next year.
“So this year, we hopefully will be able to make about 5,000 Optimus robots. We’re technically aiming for enough parts to make 10,000, maybe 12,000, but since it’s a totally new product with a totally new, like everything is totally new, I’ll say we’re succeeding if we get to half go the 10,000.
“But even 5,000 robots, that’s the size of a Roman legion, FYI, which is like a little scary thought. Like a whole legion of robots, I’ll be like ‘whoa.’ But I think we will literally build a legion, at least one legion of robots this year, and then probably 10 legions next year. I think it’s kind of a cool unit, you know? Units of legion. So probably 50,000-ish next year,” Musk said.
Tesla’s Q1 2025 All-Hands Meeting can be viewed below.
News
Tesla Shanghai Megafactory starts exporting Megapacks, first to Australia
Tesla Asia celebrated the Shanghai Megafactory’s first Megapack exports on X.
Tesla has begun exporting Megapack battery systems from its Shanghai Megafactory, with the first shipment departing for Australia on Friday. This marks a key step in Tesla Energy’s expansion into the global energy storage industry, utilizing its new China-based Megafactory to supply several new markets.
Tesla Asia celebrated the Shanghai Megafactory’s first Megapack exports through its official social media account on X.
Tesla Megapacks in Focus
The Tesla Megapack is capable of storing 3.9 MWh of energy, and they are designed for grid use. As per Tesla in its official website, each Megapack battery has enough energy to power an average of 3,600 homes for one hour. The Megapack is designed to be infinitely scalable as well, making it a good fit for large-scale sustainable energy projects.
The Shanghai Megafactory
The Shanghai Megafactory began production in early 2025, a record eight months after its May 2024 groundbreaking. With an initial output of 10,000 units annually, equal to about 40 GWh, the Shanghai Megafactory has the potential to significantly boost Tesla’s battery storage deployments.
As per a report from Xinhua News Agency, Tesla is expecting its energy deployments to rise 50% year-over-year this 2025.
Tesla Leaders on the Shanghai Megafactory
Mike Snyder, vice president of energy and charging at Tesla, previously outlined the potential of the Shanghai Megafactory. “Megafactory gives us the ability to scale production and efficiency. We can lower logistics costs as well as product costs, and grow the business to new markets,” he stated.
The Shanghai Megafactory also seems to be part of Tesla’s efforts to grow its presence in China, which was highlighted by CEO Elon Musk during a meeting with Chinese Premier Li Qiang. During their meeting, Musk reportedly stated that “Tesla is willing to deepen cooperation with China and achieve more win-win results.”
Elon Musk to file lawsuit against former US Rep Jamaal Bowman: “I’ve had enough”
Tesla aiming to produce first “legion” of Optimus robots this 2025
Tesla Shanghai Megafactory starts exporting Megapacks, first to Australia
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