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SpaceX sets Dragon reuse record, debuts drone ship on first launch in two months

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Update #2: After a 24-hour weather delay, conditions were far more favorable on August 29th, allowing a SpaceX Falcon 9 rocket to lift off for the first time in almost two months and send a cargo-filled Dragon spacecraft on its way to the International Space Station (ISS).

Aside from marking the end of SpaceX’s longest launch hiatus in two years, CRS-23’s successful liftoff also means that the company has smashed the world record for fastest orbital space capsule reuse. As part of Cargo Dragon 2’s first reuse ever, SpaceX launched Dragon C208 just seven and a half months (227d) after its first orbital reentry and splashdown, handily beating the previous record of 328 days. Additionally, flying for the fourth time, Falcon 9 booster B1064 became the first rocket to land on brand new SpaceX drone ship A Shortfall of Gravitas (ASOG) after sending Dragon C208 on its way to the ISS.

Falcon 9 and Cargo Dragon 2 streak into space. (Richard Angle)

Update: Although the weather forecast has worsened, SpaceX remains on track to attempt its first launch in eight weeks – a mission that will also smash one of the company’s orbital spacecraft reusability records.

While mostly mundane, a system preceding Tropical Storm Ida is producing conditions less than optimal for rocket launches, raising the risk of in-flight lightning strikes and the chances of Falcon 9 and Dragon flying through clouds containing precipitation (rain/ice/etc). Ultimately, that means that there’s just a 40% chance (down from 50% in the last few days) that weather conditions will be favorable for SpaceX to launch CRS-23. Regardless, barring a surprise announcement in the next few hours, it appears that there’s enough of a chance that SpaceX and NASA will still make an attempt.

If all goes according to plan, a flight-proven Falcon 9 rocket will send an upgraded Cargo Dragon on the way to orbit for the second time in seven months – almost twice as fast a turnaround as SpaceX’s ~340-day record for orbital spacecraft reuse. Tune in below around 3:20am EDT (07:20 UTC) to catch the hopeful launch live.

For the first time in more than nine weeks, SpaceX has completed a routine Falcon 9 preflight test known as a static fire and verified that the rocket is ready to launch later this week.

Save for at least one booster qualification test completed at SpaceX’s McGregor, Texas development facilities, Falcon 9’s August 25th static fire is the first since June 22nd. The upgraded Cargo Dragon space station resupply mission the rocket will support will also be SpaceX’s first launch since June 30th – the company’s longest hiatus between launches since a three-month pause that began two years ago.

Now, just a few days before that drought is expected to end, a SpaceX executive has partially explained why the company hasn’t launched a single Falcon rocket in ~60 days after completing a record 20 orbital launches in the first half of 2021.

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Speaking at the 2021 Space Symposium on August 24th, SpaceX President and COO Gwynne Shotwell revealed that the company had chosen to pause Starlink missions (representing the vast majority of its 2021 launches) and focus on preparing a new generation of satellites for flight. Believed to be called Starlink V1.5, those new satellites represent a relatively small design change save for one crucial addition: multiple lasers.

All the way back in mid-2018, SpaceX launched its very first pair of Starlink prototype satellites – spacecraft that largely functioned as expected and provided a wealth of data but were almost nothing like the Starlink V0.9 and V1.0 spacecraft SpaceX would eventually start launching in 2019. Nevertheless, they did carry sets of small lasers generally known as optical intersatellite links or OISLs for short. Not radically dissimilar to the hundreds of thousands of miles of fiber optic cables that make up the backbone of the internet, lasers operating in the vacuum of space can effectively mirror the extraordinary bandwidth and performance offered by fiber connections – but wirelessly.

Instead of carefully insulated cables filled with tiny threads of glass, which really just serve as a controlled environment for light-based communications, OISLs enable a similar feat by replacing cables with extraordinarily precise mechanisms capable of aiming lasers with sub-millimeter precision from dozens or hundreds of miles away. As a result, laser interlinks are fairly complex and expensive devices – not something currently economical to install on thousands of satellites mainly focused on affordability.

SpaceX, of course, has wanted to install unprecedentedly affordable laser interlinks on thousands of Starlink satellites for as long as the constellation has been publicly discussed. If realized, it would create an extraordinary orbital mesh network that would allow Starlink to self-route a large portion of user communications without the need for a colossal network of tens of thousands of ground stations covering every inch of Earth – land, sea, ice, and all. A Starlink constellation with near-universal laser interlinks could also potentially allow the constellation to not only match – but beat by a large margin – the latency of best-case terrestrial fiber-optic connections.

After effectively completing Starlink’s first ‘shell’ of satellites earlier this year, SpaceX shifted its focus to preparing for polar Starlink launches from both its west and east coast facilities. While the first shell lacked interlinks entirely, SpaceX appears to have decided that all polar Starlink satellites will be launched with its own custom-built space lasers, even if that means delaying Starlink launches until those lasers are ready for action. Due to the fact that the vast majority of SpaceX’s launches as of late have been its own Starlink missions, the company’s Falcon rockets simply haven’t had anything to launch.

Cargo Dragon 2 capsule C208 and Falcon 9 booster B1061 head to Pad 39A. (SpaceX)
C208, the first Cargo Dragon 2 capsule ever built or flown, is on track to smash SpaceX’s orbital spacecraft turnaround record. (SpaceX)

That should change on August 28th, when a thrice-flown Falcon 9 booster launches a refurbished spacecraft on its second orbital space station resupply – a first for SpaceX’s upgraded Cargo Dragon 2 vehicle. A Shortfall of Gravitas (ASOG), SpaceX’s newest drone ship, will also be supporting its first Falcon landing ever as part of CRS-23, hopefully recovering Falcon 9 booster B1064 for a fifth launch later this year.

Tune in around 3:20am (07:20 UTC) on Saturday, August 28th to watch SpaceX’s first launch in two months live.

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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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Cybertruck

Tesla Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

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

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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SpaceX has solved Starship’s biggest challenge, Elon Musk says

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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