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SpaceX nails second Falcon 9 landing in 48 hours, fairing catch foiled by weather

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Just a handful of days after SpaceX’s second-ever successful launch and landing of their upgraded Falcon 9 Block 5, the company has completed the same feat on the opposite side of the United States, debuting the Block 5 rocket with a launch and booster recovery from California’s Vandenberg Air Force Base (VAFB).

The booster in question, Falcon 9 B1048, is the third Block 5 booster to roll off of SpaceX’s Hawthorne, CA assembly line and is now the first Block 5 rocket to launch from the company’s California launch facilities. On the opposite coast, SpaceX’s second Block 5 Falcon 9 booster (B1047) completed its own successful launch and landing, lofting the heaviest commercial satellite to ever reach orbit (Telstar 19V).

While weather during camera setup was absolutely spectacular, the predawn launch window meant that no sun was available to force the ever-present VAFB fog back over the ocean. (Pauline Acalin)

Seven months, fourteen launches

Today’s near-flawless predawn mission saw Falcon 9 place 10 Iridium NEXT satellites in a polar Earth orbit, during which the rocket’s Block 5 booster completed the first landing on Just Read The Instructions in nearly ten months and Mr Steven made his first attempt at catching a parasailing Falcon fairing with his massive net and arms upgrades. Those upgrades, tracked tirelessly by Teslarati photographer Pauline Acalin for the better part of July, took barely a month to go from a clean slate (old arms and net fully uninstalled) to operational, fairing-catching status, an ode to the incredible pace at which SpaceX moves.

Sadly, the vessel’s Iridium-7 fairing catch attempt was sullied from the start by inclement weather – primarily wind shear –  that significantly hampered the accuracy of each fairing halve’s parafoil guidance, meaning that Mr Steven’s crew did see the parasailing halves touch down, but too far away to catch them in Mr Steven’s large net. Falcon 9 B1048 had its own difficulties thanks to what engineer and webcast host John Insprucker described as “the worst weather [SpaceX] has ever had” for a Falcon booster landing. Nevertheless, Falcon 9 appeared to stick an off-center but plenty accurate landing aboard drone ship JRTI, although SpaceX technicians are likely going to wish they had the same robotic stage securer located aboard OCISLY on the opposite coast.

 

Just Read The Instructions, on the other hand, was similarly tracked but primarily to verify that nothing was happening – the vessel’s last operational trip to the Pacific Ocean dates back to the first half of October 2017. Since then, SpaceX began a process of intentionally expending Falcon 9 boosters that had already flown once before, choosing to essentially start from scratch with a fresh fleet of highly reliable and reusable Falcon 9 Block 5 boosters rather than recover older versions of the rocket and attempt to refurbish them beyond the scope of their designed lifespans.

The Block 5 design, however, has taken the countless lessons-learned from flying and reflying previous versions of Falcon 9 and rolled them all into one (relatively) final iteration of the ever-changing rocket. With any luck and at least a little more iteration, Falcon 9 Block 5 boosters should be capable of launching anywhere from 10 to 100 times, 10 times with minimal or no refurbishment and 100 times with more regular maintenance, much like high-performance jet aircraft do today.

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With three successful launches of new Block 5 boosters now under the new version’s belt, it’s safe to say that the rocket is off to an extremely good start. The most important milestones to watch for over the next several weeks and months will be the first reflight of a recovered Block 5 rocket, the first reuse of a Falcon 9 payload fairing, and then the first third/fourth/fifth/etc. reuse of Block 5 booster. On the horizon, of course, is SpaceX CEO Elon Musk’s challenge to launch a Falcon 9 Block 5 booster two times in less than 24 hours, and do so before the end of 2019.

Roughly 3,000 miles to the East, SpaceX’s just-recovered Florida Block 5 booster wrapped up a picture-perfect arrival in Port Canaveral aboard drone ship Of Course I Still Love You at the exact same time as another Block 5 rocket was launching (and landing) on the opposite coast.

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For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet (including fairing catcher Mr Steven), check out our brand new LaunchPad and LandingZone newsletters!

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.

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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.

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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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