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SpaceX’s new Falcon 9 fairing recovery ship kicks off sea trials ahead of next launch

Fairing catcher GO Ms. Chief - the latest addition to SpaceX's rocket recovery fleet - departed Port Canaveral for sea trials on October 23rd. (Richard Angle - Teslarati)

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After a brief installation period, SpaceX’s second Falcon 9 fairing-catching ship departed Port Canaveral to begin sea trials with its new net and arms, a critical step before it can be declared ready to attempt its first fairing recovery.

Known as GO Ms. Chief, the ship’s first opportunity could come as early as a few weeks from now, potentially marking a major milestone for SpaceX’s fairing recovery and reuse program.

On his first shoot for Teslarati, photographer Richard Angle (@RDAnglePhoto) managed to capture Ms. Chief while departing Port Canaveral on October 23rd, heading a few miles off the coast to kick off sea trials likely focused on proving out a wide range of new hardware installed in the last month. Those trials began less than 24 hours after technicians installed Ms. Chief’s recovery net for the first time ever, with the ship’s subsequent trip into the Atlantic Ocean essentially marking the completion of her transformation from fast supply vessel (FSV) to SpaceX fairing catcher.

SpaceX is currently in the midst of its longest lull in launch activity since September 2016, likely triggered by the unavailability of customer payloads and the company’s own internal Starlink missions. Unfortunately, although the lull was initially expected to end as early as mid-October, the internal Starlink launch (Starlink-1) expected to lead the charge slipped about a month for unknown reasons and is now expected no earlier than November – likely in the second half of the month.

As a small consolation, Starlink-1’s launch delays mean that the newly-outfitted Ms. Chief may be able to inaugurate its new net and arms by attempting to recover one of the mission’s Falcon 9 fairing halves, while the nearly identical GO Ms. Tree attempts to snag the other half. Even if more tweaking and sea trials are needed to prove her readiness, SpaceX’s next launch is still likely several weeks away, hopefully giving the company’s recovery team plenty of time to prepare Ms. Chief and practice recovery operations.

As of October 2019, SpaceX has successfully caught two Falcon fairing halves during the company’s last two back-to-back recovery attempts, beginning with a Falcon Heavy fairing half caught on June 25th and ending with a Falcon 9 fairing half caught on August 7th. Beyond Ms. Tree’s two catches, SpaceX has successfully recovered a number of additional fairing halves after they performed soft landings in the Atlantic Ocean, including both halves launched in May 2019 for the company’s first dedicated Starlink mission.

Given that SpaceX has technically caught two halves of a payload fairing, it’s possible that one is female and the other male, potentially meaning that one of SpaceX’s upcoming Starlink launches could feature the first fully-reused Falcon 9 fairing. Regardless, assuming one or both were recovered in good condition, it’s even more likely that at least one half (with the other half new) will be reused on one (or both) of those upcoming flights.

Said by CEO Elon Musk to make up approximately 10% of the cost of a new Falcon 9 (~$6M), routine fairing recovery and reuse would close the last remaining loop for Falcon 9 reusability, with boosters and fairings accounting for roughly 75-80% of the total cost of the rocket. SpaceX has no plans to attempt to recover or reuse Falcon 9’s second stage, choosing instead to prioritize development of the fully-reusable Starship launch vehicle.

Preparing the oven-cured carbon composite shells that make up the bulk of SpaceX’s Falcon fairings takes a disproportionate amount of time and factory floor space. Even if Falcon fairings can only be reused once or twice, it would effectively double or triple the effectiveness of the current manufacturing apparatus, cutting the relative cost of production by 50% or more for the price of operating Ms. Tree and Ms. Chief.

Fairing reuse will be a critical part of ensuring that the first phase of SpaceX’s Starlink constellation can be launched as affordably as possible on Falcon 9. With at least 24 launches needed to cover most populated areas, cutting even a few million dollars per launch could produce savings on the order of $100M, equivalent to the production cost of 100-200 Starlink satellites.

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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 Optimus Gen 3 shows off a cleaner, factory-ready design in new app discovery

Renders hidden inside Tesla’s Android app show Optimus Gen 3’s design before any official reveal.

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla may have accidentally given a first look at its newest Optimus Gen 3 humanoid robot when photos were found in the Tesla smartphone app.

Design files tucked inside a recent Android version of the Tesla app appear to show the third generation humanoid robot next to the older Gen 2.5 prototype. The assets were extracted from the app package by Tesla community member @wholemars, who posted the renders on X late Tuesday night before deleting them. The Tesla Newswire reshared the side by side comparison on Wednesday, and the images have circulated widely since.

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

The files are labeled “gen3” and were built as models for Tesla app’s own interface, as validated directly by Grok to be official.

The comparison shows a robot that looks built for a factory line rather than a lab bench. Gen 2.5’s exposed mechanical linkages and gold plating on the knees and shins are gone. In their place, Gen 3 uses matte black fairings on the lower legs, paired with a more contoured champagne gold body. Flexible covers now seal the joint where the torso meets the upper thighs, keeping bearings and moving parts sealed from debris and unnecessary contact.

The body panels fit more tightly, and the hands, which Tesla has said carry 22 degrees of freedom, look far more refined than those on earlier units.

This most recent leak fills a gap Tesla has left open for most of the year. Elon Musk said on March 31 that Optimus 3 was walking around but needed “some finishing touches” before it could be shown, a delay Teslarati covered when Tesla missed its first quarter reveal target. Musk later said Tesla would hold the design back until closer to production, partly to keep competitors from copying it. No reveal date has been announced.

The app itself has been preparing for Optimus for months. In July, code in the Tesla app pointed to a dedicated robot phone key, a consent screen for collecting video and spatial data while Optimus works inside a home, and an alert system for low battery and mechanical faults. Finished 3D models of Gen 3 suggest the interface owners will eventually use is moving past placeholder code toward something Tesla intends to ship.

Manufacturing is moving in parallel. Tesla tore out the original Model S and Model X lines at Fremont this summer to make room for Optimus production, with a planned capacity of one million robots a year. At Giga Texas, the steel frame of a dedicated Optimus factory is nearing completion ahead of a targeted 2027 start, with Musk pointing to an eventual output of 10 million units annually.

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Tesla Semi lands the biggest electric truck deal in U.S. history

Tesla leads a record 2,500 truck order, but not every truck will be a Semi.

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Tesla has landed the largest electric truck order in U.S. history. ZET SCALE, a new alliance of shippers and carriers, named Tesla its primary manufacturer on Tuesday for an initial order of 2,500 electric Class 8 trucks. The deal alone would nearly double the number of electric heavy trucks operating in the country.

According to the press release from Catalyst Mobility, the nonprofit formerly known as CALSTART, Kenworth, RIDE and Volvo were also selected as secondary manufacturers that carriers can pick if their operations call for it. No split between the four brands has been published, so the exact number of Semis in the order is not yet known.

Tesla won the top slot through a competitive request for proposals. The alliance, which Catalyst Mobility runs with the Smart Freight Centre, scored bidders on price, range, charging capability and production capacity. Pooling freight demand from founding shippers, including Microsoft and PepsiCo, let every truck maker bid lower than it would for a single fleet. “The Tesla Semi is designed for lower cost per mile operations than diesel,” said Dan Priestley, director of the Tesla Semi program, as noted in the press release.

The financing is built to pull in carriers who have avoided electric trucks. ZET Financial is issuing the purchase order for all 2,500 units and will place them with fleets through a fair market value lease. The trucks will be deployed over the next few years across 10 freight hubs in Los Angeles, Stockton, Bakersfield, Seattle and Tacoma, Houston, Dallas, San Antonio, Chicago, Atlanta, and the Newark and New York area. ZET SCALE says the first order is only the opening round, with a longer term goal of 10,000 trucks or more.

Even if Tesla ends up with only a majority share, it would still be the biggest Semi deal to date. Einride’s 500 unit order in August was the previous record, and WattEV’s 370 truck order in May was the largest California deal at the time. Einride’s CEO has since said he expects all 500 trucks delivered by the end of 2027.

The announcement lands two days before Tesla formally inaugurates its Semi factory in Nevada on September 24. The 1.7 million square foot plant sits next to Gigafactory Nevada’s 4680 cell lines and is designed for 50,000 trucks a year.

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

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Credit: Grok

Tesla has expanded Grok from an in-car chatbot into a hands-free work assistant. On September 22, Tesla officially launched Grok Bot capability, confirming that drivers can now manage email, calendars, files, chats, and tasks by voice and then hand more ambitious errands to the AI-fueled productivity cheat code.

Grok itself is built by xAI. The new car features split into two layers: Connectors link Grok to outside accounts. Grok Bot, currently limited to SuperGrok Heavy subscribers, can complete multi-step tasks such as placing a usual coffee order, booking a reservation, or scheduling an appointment. It truly puts the driver in a nearly complete hands-free driving and productivity setting, with ironically the only task truly requiring your hands being to touch the “Start Self-Driving” button.

We were granted access to Grok Bot’s Tesla integration a few weeks back, and we’ve been able to do a handful of things with it. On a handful of occasions, we’ve used it to order food and have it ready for pickup slightly later into the evening; we’ve managed to pick up groceries after a day of errands with Grok Bot, and outside of the car, it’s helped with budgeting and even my fantasy football draft.

Tesla shows another way to utilize it: in their demo, a driver says “Hey Grok,” asks the assistant to check an inbox, and hears that a message concerns a weekend reservation. Grok then scans the calendar, reports no conflicts, and confirms the Tahoe trip is clear. It can also add check-in details to a road-trip itinerary. The point is not novelty chat. It is keeping eyes on the road, or on Full Self-Driving, while the car handles the paperwork of a trip:

This Grok rollout is not a gadget add-on as much as it is Tesla’s thesis in software form: the car should stop being a machine you operate and start being a room you occupy.

Connectors and Grok Bot treat the cabin as an office that happens to move, and that has truly been Tesla’s intention for years now. The car has slowly become an extension of a home more than a vehicle. Inbox, calendar, groceries, takeout, and reservations become voice work, not dashboard chores that you need to do before you get in your car.

Responsibility shifts from the driver to the stack, and as many Tesla owners rely on FSD for travel, Grok Bot now handles the monotony of dinner reservations or appointments.

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