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SpaceX delivers largest commercial satellite in kick off of Falcon 9 marathon

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SpaceX has successfully completed its 13th launch of 2018, kicking off a marathon of three new Falcon 9 Block 5 booster debuts with the launch of the Telstar 19V communications satellite, potentially breaking the record for the largest commercial satellite ever launched at 7000 kg (15,500 lb).

Despite the heft of its payload and partially thanks to a slightly lower parking orbit for the satellite, Falcon 9 booster B1047 – the second Block 5 booster to roll off the assembly line – managed to successfully land aboard the autonomous spaceport drone ship (ASDS) Of Course I Still Love You (OCISLY), stationed approximately 650 km (400 mi) off the Florida coast at launch time.

While the booster was unable to maintain a live video feed through its high-speed reentry and Atlantic landing, SpaceX’s cameras on OCISLY managed to reconnect a few seconds after touchdown to show the 50-meter (160-foot) tall rocket safely resting on the drone ship. As the webcast host noted, Falcon 9 Block 5 features a number of prominent upgrades designed to enable levels of reusability and reliability essentially unprecedented in the world of orbital rocketry.

Rocket trials

Now more than two months after the first Block 5 booster’s – B1046 – debut in May 2018, the software engineer hosting SpaceX’s Telstar 19V webcast was likely speaking more from a place of experience than of hope. Per CEO Elon Musk’s press call just prior to Block 5’s debut, he noted that SpaceX intended to conduct an extensive analysis of that pathfinder booster, including significant disassembly and perhaps some limited destructive testing of certain critical or high-risk components. Musk didn’t expect B1046 to fly for at least another “couple of months”.

This is critical because SpaceX’s manifest over the next several weeks is fairly aggressive – Iridium-7 is scheduled to lift off from Vandenberg, CA three days from today (July 25th), the next Florida launch is aiming for a static fire next weekend and a launch NET 1:19 am EDT August 2, and the second imminent Florida mission is penciled in for launch NET 11:35 pm EDT August 17. Those rapid-fire Florida launches will push both SpaceX’s pad and drone ship turnaround capabilities to their limits, requiring almost non-stop work to ensure both are available for the next mission in two weeks or less.

Not to be (at least relatively) one-upped, SpaceX’s Vandenberg launch pad – known as SLC-4E – is scheduled to push its own turnaround limits by flying two missions in roughly 40 days, just shy of the current SpaceX record of 36 days between launches. Perhaps more excitingly, that September 4 SAOCOM 1A mission looks like a prime candidate for the debut of SpaceX’s yet-unused Californian landing zone, barely spitting distance from the SLC-4E launch pad.

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Still, the question remains: what boosters are going to launch these four missions?

  • B1051 is not believed to have left the Hawthorne, CA factory yet, and has been stated by NASA to be reserved for the first uncrewed Crew Dragon mission (DM-1), unlikely to occur before Q4 2018.
  • B1050 is currently on-stand in McGregor, TX and is likely to be shipped to a launch pad within a week or two.
  • B1049 was almost certainly shipped to Florida to support either of the two upcoming August launches.
  • B1048 will launch Iridium-7 on July 25, land on Just Read The Instructions, and likely remain in California for future VAFB missions.
  • B1047 just successfully launched Telstar 19V (July 22) and will be brought back to Port Canaveral over the next several days before heading to one of SpaceX’s Florida refurbishment facilities, presumably to prepare for an imminent future launch.
  • B1046 is likely disassembled in Hawthorne, CA, unable to support a launch for another few weeks – perhaps it’s nearly ready, however

 

Three Falcon 9 boosters captured in various states of transport and testing over the last six weeks, two of which are B1047 and B1048. (Teslarati/Tesla Motors Club/Reddit/Facebook)

 

Put simply, it seems almost impossible for SpaceX to accomplish its ambitious manifest over the next 4-6 weeks without reusing a freshly-recovered Falcon 9 Block 5 booster. B1046 is a possibility, as is B1047 or B1048, although the latter two options would smash SpaceX’s previous record for Falcon booster turnaround (~70 days) by more than half, requiring  in a return to shore, refurbishment or nondestructive analysis, and preparation for a static fire in as few as ~14-21 days.

Regardless, B1047’s successful Telstar 19V launch and landing have kicked off what is bound to be an extremely exciting period for SpaceX and its aspirations of highly-reusable rocketry.

Follow us for live updates, peeks behind the scenes, and photos from Teslarati’s East and West Coast photographers

Teslarati   –   Instagram – Twitter

Tom Cross – Twitter

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Pauline Acalin – Twitter

Eric Ralph – Twitter

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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Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says

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Credit: United Airlines

United Airlines CEO Scott Kirby said that SpaceX’s Starlink satellite internet is its leading competitive advantage in the U.S. airline industry. However, in recent comments, while he described the service as “the biggest competitive advantage” the carrier currently holds, he also acknowledged that the edge is temporary.

“…everybody eventually is going to have high-speed low earth orbit internet connectivity. It’s going to be a must-have. We are going to have a few years of being the only airline that has it at scale, and that’s our mission,” Kirby said. Until everyone has it, United aims to capitalize on its head start by converting trial users into long-term loyal customers.

United has moved faster than its rivals on Starlink installations. As of mid-to-late October 2026, the system was on roughly 43 percent of its fleet, with plans to reach 61 percent by year-end, 87 percent by June 2027, and full fleet coverage by the end of next year.

The airline already operates more Starlink-equipped flights than the rest of the U.S. industry combined. Los Angeles International Airport is scheduled to become United’s first 100 percent Starlink hub in the first half of 2027, and the carrier’s app will display the likelihood that any given flight has the service.

Kirby has pointed to early evidence that the offering influences booking decisions. Some passengers loyal to other airlines are already switching flights for Starlink connectivity, something the airline, along with American Airlines, has tried to leverage against competing airlines. Both companies used status-match programs, and some of those customers are pursuing company-specific credit cards, which signals an intent to stay.

Once onboard, these customers encounter the airline’s broader investments in aircraft, larger seat-back screens, oversized bins, connection tools, and a mobile app that Kirby says outperforms competitors. Wi-Fi satisfaction scores on Starlink-equipped planes have been reported to be nearly double those on aircraft with other systems.

Competitors are moving slowly to do the same. Southwest Airlines began installations in 2025 and expects to complete them soon. Delta is pursuing Amazon’s Leo system, while American expects to start Starlink work in early 2027 and has not yet detailed regional-fleet plans. This timeline gap gives United a multi-year window in which it remains the only major U.S. carrier offering Starlink at scale.

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Kirby has framed the strategy as pressing that advantage while simultaneously widening gaps in other technology areas so that customers who try United for the Wi-Fi remain for the overall experience.

The approach reflects a calculated bet that superior in-flight connectivity can accelerate share gains and support longer-term financial targets, including a 10 percent pre-tax margin goal.

High-speed internet is particularly valued by premium and business travelers who can work or stream reliably. As low-Earth-orbit service becomes ubiquitous, the temporary nature of the pure connectivity edge means United’s retention will depend on whether its other product and operational improvements keep pace.

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Tesla Cybercab’s unorthodox paint process explained

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Credit: Tesla

Tesla Cybercab skips the traditional paint shop entirely, marking an unorthodox process for coloring the fully autonomous vehicle. However, the decision was a smart one, as it slashed factory costs, floor space utilization, and complexity, since Tesla relied on specialized alloys and in-mold coloring.

Munro Live was given the opportunity to do a factory walkthrough with Tesla Vice President of Vehicle Engineering Lars Moravy, who explained and detailed how Cybercab production at Giga Texas eliminates one of the automotive manufacturing industry’s most expensive and space-hungry elements.

A conventional paint line can cost hundreds of millions of dollars and require a million man-hours to build. Moravy framed the choice around Tesla’s core rule: “Question the requirements: why do you need paint?”

The structural answer lies in material selection. The aluminum alloys used in Cybercab’s front and rear castings do not oxidize and lose strength over time, the way many common automotive aluminum alloys do. Only the side modules, built around hot-stamped boron-steel door rings, receive an anti-corrosion e-coat, or dip coat. Front and rear modules skip coating altogether.

Model Y and Model 3 bodies, by contrast, are fully coated and painted.

Exterior colors come from the plastics shop, which Tesla engineers described as “our paint shop” for the Cybercab. Body panels are produced via reaction injection molding, referred to as RIM. Color is then mixed into a polyurethane resin at the mix head immediately before injection, so the panel emerges already colored with a Class-A surface.

Robots trim overflow to control sink marks and flow lines. The process avoids conventional spray-paint defects like orange peel and paint bleed. Scratches can still be repaired with compatible coatings that behave “basically like paint.” Because color is integral rather than a surface layer, shallow scratches do not expose a contrasting undercoat.

The secret behind Tesla’s Cybercab Gold goes well beyond just the color

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Tesla has also explored related approaches, including in-mold lamination and painted films on stamped panels.

The manufacturing payoff is substantial because removing the paint shop, combined with the “unboxed” modular process that builds and tests front, rear, side, and center modules in parallel before a short final assembly, cuts factory floor space per vehicle by about 50 percent.

Final assembly itself uses only about 25 automated stations, far fewer than the typical Model Y line, and the overall line runs at about 78 percent automation, Moravy said. The approach also eliminates volatile organic compound emissions associated with traditional spray painting for these panels and shortens the coloring cycle from hours to minutes.

Cybercab’s paint strategy is clearly less about aesthetics than about systematically deleting capital-intensive, energy-heavy, and space-consuming steps once material science and process design make them unnecessary. It is a concrete example of Tesla applying first-principles questioning to one of the auto industry’s most entrenched factory requirements.

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Tesla has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

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Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

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The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

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