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SpaceX readies 4th Falcon 9 booster for 10th launch and landing [webcast]

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Update: SpaceX has delayed Starlink 4-6 and Falcon 9 B1060’s tenth launch and landing to a backup window scheduled no earlier than (NET) 9:02 pm EST, Tuesday, January 18th (02:04 UTC 19 Jan).

Initially aiming for January 17th, SpaceX pushed the mission to 7:04 pm EST, January 18th for “more favorable weather conditions for liftoff and booster recovery.” A backup window two hours later on the same day was likely selected for similar reasons. Tune in around 8:45 pm EST (01:45 UTC) to watch Falcon 9 B1060’s tenth launch and landing attempt live.

Four days after Falcon 9 B1058 became the third SpaceX booster to complete ten orbital-class launches, the company is set to repeat the feat a fourth time.

Unofficially revealed by airspace and maritime safety alerts on January 12th, SpaceX has confirmed plans to launch Starlink 4-6 – another batch of 49 laser-linked V1.5 satellites – no earlier than (NET) 7:26 pm EST, Monday, January 17th (00:26 UTC 18 Jan) from Kennedy Space Center Pad 39A. The same pad supported an identical launch (Starlink 4-5) on January 6th, requiring a brisk 11-day turnaround for a pad that’s all-time record is two Falcon launches in 10 days.

While technically “just” another Starlink launch, the mission will mark the first time two Falcon 9 boosters have launched for the tenth time back to back. On January 13th, Falcon 9 B1058 helped deliver 105 small rideshare satellites to orbit, completing its tenth successful launch and landing in the process. While there are only two other ten-flight boosters to compare against, B1058 crossed the milestone more than a third faster than either of its siblings, launching ten times in 19 months or once every ~59 days for the duration of its life.

Falcon 9 B1058’s tenth successful landing, January 13th. (SpaceX)

When Falcon 9 B1060 lifts off with Starlink 4-6 on January 17th, 2022, it will do so in 18 months (~81 weeks), beating B1058’s days-old record (19 months or ~85 weeks) by about a month. Though there are several younger, less-flown boosters in SpaceX’s current Falcon fleet, none of them appear to be on track to more than marginally beat or match the records about to be set by B1058 and B1060. Based on SpaceX’s twice-achieved 27-day Falcon 9 turnaround record, it might technically be possible for the same booster to complete 10 launches in as few as 270 days (~39 weeks), employees have described those record turnarounds as “a mad rush” – probably not a sustainable pace for the current workforce, in other words.

Nonetheless, even if evidence continues to grow that the current iteration of Falcon Block 5 boosters are unlikely to average more than one launch every 50-60 days over their lives, SpaceX could still theoretically achieve an eyewatering launch cadence. For example, if SpaceX’s current fleet of nine operational Falcon boosters (including one converted Falcon Heavy core) can each achieve an average of one launch every 60 days starting now, SpaceX could feasibly launch more than once per week or ~54 times per year. If SpaceX also converts Falcon Heavy core B1053 into a Falcon 9, damaged Falcon 9 booster B1069 is able to enter the fleet, and the average turnaround time drops to 50 days, that 11-booster fleet could support up to 80 launches per year.

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Mission complete! Taken by Airmen Alex Preisser, this photo shows B1052 and B1053 shortly after coming to a rest at SpaceX's Landing Zones.
SpaceX has a minimum of six new Falcon Heavy cores and one new Falcon 9 booster nearly ready for 2022 launch debuts. It’s unlikely that the company will slow down production, so another 5+ could be built and qualified before the end of 2022. (USAF – Alex Preisser)
It’s likely that B1053 will join B1053 and also become a Falcon 9 booster. (Richard Angle)

SpaceX’s three Falcon launch pads could theoretically support up to 90 launches per year if every single turnaround was as fast as each pad’s all-time record and no extended downtime was ever needed. In other words, in spite of just how far the Falcon Block 5 design appears to be from CEO Elon Musk’s long-stated dream of daily reuse, a fleet of just 15 Block 5 boosters averaging a conservative 60 days per launch could achieve an annual cadence that would force SpaceX to upgrade its launch pads to go any higher.

With Starship on the horizon, though, it’s no longer clear that SpaceX actually wants to push the Falcon family’s envelope to the point that another round of significant vehicle or pad upgrades are required. Unless Starship suffers catastrophic setbacks causing years of delays, it’s more likely than not that the Falcon family will peak around 60 launches per year (still incredibly impressive) before its likely retirement.

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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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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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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