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Pictured here attempting its first landing in June 2020, Falcon 9 booster B1060 is about to launch twice in four weeks. (SpaceX) Pictured here attempting its first landing in June 2020, Falcon 9 booster B1060 is about to launch twice in four weeks. (SpaceX)

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SpaceX fires up Falcon 9 for first flight-proven ‘national security’ launch

Close sibling to B1060, pictured here, Falcon 9 booster B1062 is set to become the first commercial flight-proven rocket to launch a US 'national security' satellite later this week. (SpaceX)

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On June 12th, SpaceX successfully fired up a once-flown Falcon 9 booster in the lead-up to the company’s fourth launch of an upgraded GPS III navigation satellite for the US military.

Dating back several years, SpaceX has won a vast majority of GPS III launches thanks to Falcon 9’s exceptional combination of reliability and affordability, securing all five competitively-awarded contracts. The company aced its first GPS III launch in December 2019, expending a brand new Falcon 9 booster (B1054) due to customer – not performance – requirements necessary to ensure extreme margins in the event of some kind of anomaly or underperformance during launch.

In June 2020, SpaceX once again launched a GPS III satellite for the US military, though this time the company was allowed to attempt to land the Falcon 9 booster supporting the mission – which it successfully recovered without issue. Less than five months after GPS III SV03’s successful launch, SpaceX turned around and launched GPS III SV04 – again with an all-new Falcon 9 rocket – and recovered the booster at sea. A few months prior, however, the US Space and Missile Systems Center (SMC) announced a contract modification that would allow SpaceX to begin reusing Falcon 9 boosters on National Security Space Launch (NSSL) missions – beginning with the company’s fourth GPS III launch.

Seven months later, SMC revealed that it has officially cleared SpaceX to begin launching GPS III (and other official NSSL) satellites on flight-proven Falcon rockets. Notably, that might include a Falcon Heavy launch – USSF-52 – planned as early as January 2022 that could reuse two new side boosters scheduled to debut on USSF-44 as early as October 2021.

In the meantime, though, GPS III SV05 – scheduled to launch no earlier than (NET) 12:09 pm EDT (16:09 UTC), Thursday, June 17th – is just two days away from becoming the first NSSL (formerly EELV) satellite to launch on a flight-proven commercial rocket. GPS III SV05 will reuse the same Falcon 9 booster (B1062) that successfully launched GPS III SV04 seven months prior.

While an extremely slow turnaround relative to any other modern Falcon 9 or Falcon Heavy booster, those seven months mainly gave the US military margin to fully certify flight-proven Falcons and satellite manufacturer Lockheed Martin time to deal with shortage and coronavirus-related delays. On June 12th, after rolling out to SpaceX’s Cape Canaveral LC-40 launch pad, GPS III SV05’s Falcon 9 rocket completed a wet dress rehearsal that culminated in a successful several-second static fire of booster B1062.

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Now cleared for flight, Falcon 9 will be brought horizontal and roll back to LC-40’s integration hangar, where SpaceX will install the encapsulated GPS III SV05 satellite and payload fairing on top of the rocket’s expendable second stage.

The integrated payload assembly rolled from a nearby payload processing facility to LC-40 on June 13th, giving SpaceX four days to complete integration, roll Falcon 9 back out to the launch pad, and prepare the rocket for flight. Now alone on the East Coast for the first time in 12 months, drone ship Just Read The Instructions (JRTI) departed Port Canaveral for the GPS III SV05 booster recovery zone on the same day, followed by the latest in a line of temporary fairing recovery ships on June 14th to scoop the mission’s nosecone halves out of the Atlantic.

L-3 weather forecasts predict a 40% chance of delay on June 17th, improving to 30% on June 18th. Stay tuned for webcast details as SpaceX nears the first of many flight-proven launches for the US military.

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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New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

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

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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