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SpaceX Falcon 9 rocket shown off in unprecedented detail ahead of next US Air Force launch

Via the US Air Force, SpaceX has published some of the best views ever of Falcon 9 Block 5 rocket production. (SpaceX)

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The United States Air Force (USAF) has published a number of spectacular photos shared by SpaceX, revealing some unprecedentedly detailed views of a Falcon 9 rocket in various stages of manufacturing.

Likely taken in and around SpaceX’s massive Hawthorne, California rocket factory and headquarters and McGregor, Texas test facilities in recent weeks, these new photos show the work being done behind the scenes to prepare a brand new Falcon 9 rocket for SpaceX’s next US Air Force launch. Over the last few years, the extremely competitive Falcon 9 rocket has secured SpaceX up to five launch contracts for the USAF’s next-generation GPS III satellite constellation.

Made up of three explicit contracts and two contract options to be exercised (or discarded) later on, SpaceX completed the first of those contracts in December 2018, successfully launching GPS III SV01 – the first of 32 planned satellites. As evidenced by the name, GPS III is the latest iteration of US Global Positioning System satellites and should offer better security, a greater resistance to jamming and interference, and improved navigational accuracy. Unfortunately, it could be several years to half a decade or more before civilian users begin to see the benefits from GPS III, but chances are good that SpaceX will come to launch a vast majority of the upgraded satellites.

https://www.facebook.com/SpaceandMissileSystemsCenter/posts/2933925223304839

According to the post that accompanied the photos published by the Space and Missile Systems Center (SMC), SpaceX’s second USAF GPS III mission – this time carrying Space Vehicle 03 (SV03) – is scheduled to launch no earlier than (NET) the end of Q1 2020. Preparations are reportedly well underway for the critical launch: SMC says that SpaceX has already delivered the mission’s new Falcon 9 Block 5 booster from its Hawthorne factory to McGregor, Texas, where technicians are now preparing the reusable rocket for a routine static fire test before shipping it east to Florida.

Additionally, the GPS III SV03 mission’s Falcon 9 payload fairing is apparently already at SpaceX’s Cape Canaveral Air Force Station facilities, likely waiting for Air Force to ship the large satellite to Florida. If identical to SpaceX’s first GPS III launch, the GPS III SV03 spacecraft will weigh approximately 3800 kg (8400 lb) and will be launched to an elliptical orbit measuring some 1000 km by 20,200 km (620 mi x 12,500 mi).

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Falcon 9’s GPS III SV03 payload fairing has already arrived in Florida ahead of SpaceX’s next USAF launch. (SpaceX)

Astute observers will notice that both the GPS III satellite mass and the orbit it’s heading to are significantly lower than an array of prior missions that have launched heavier satellites much higher and still recovered the Falcon 9 booster along the way. SpaceX’s first GPS III launch was particularly exceptional because it marked the first and only time that a new Falcon 9 Block 5 rocket was intentionally expended without any attempt to land the booster.

In fact, Falcon 9 booster B1054 didn’t even have a semblance of landing legs or grid fins installed, a testament to the certainty of its premature demise. Thankfully, whatever the dubiously technical reasons that led to B1054’s demise, it appears that SpaceX may actually be allowed to recover the Falcon 9 booster (likely B1060 or B1061) assigned to launch GPS III SV03. Although nothing has actually been said along those lines, the Falcon 9 booster pictured in the middle photo below – implied to be the Air Force’s next GPS launch vehicle – clearly has some of the basic hardware needed for landing legs.

Falcon 9 B1054 was almost completely smooth, lacking even the hint of the hardware needed for landing legs. (SpaceX)
B1060(?), however, clearly has bits of landing leg hardware installed, visible as small black bars on the far left (aft end) of the rocket. (SpaceX)
Pictured here on Falcon 9 B1056, those black bars serve as a seal and thermal protection, protecting the sensitive leg innards during launch and reentry. (Teslarati)

As such, there is at least a small excuse to preserve hope that SpaceX’s next Falcon 9 GPS III launch will feature a booster landing, thus preventing a premature and extremely wasteful demise after just a single launch. Even if the US Air Force never actually qualifies flight-proven commercial rockets to launch its payloads, the recovered booster should be able to support anywhere from several to 90+ additional launches before SpaceX actually needs to retire or expend the booster.

Aside from the unexpected insight into the next USAF GPS III launch, SpaceX also let the SMC publish what are perhaps the most detailed public photos of a Falcon 9 octaweb – the business end of a booster – ever. (SpaceX)

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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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Tesla hints at Starlink integration with recent patent

“By employing polymer blends, some examples enable RF transmission from all the modules to satellites and other communication devices both inside and outside the vehicle.”

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Credit: Grok

Tesla hinted at a potential Starlink internet terminal integration within its vehicles in a recent patent, which describes a vehicle roof assembly with integrated radio frequency (RF) transparency.

The patent, which is Pub. No U.S. 2025/0368267 describes a new vehicle roof that is made of RF-transparent polymer materials, allowing and “facilitating clear communication with external devices and satellites.”

Tesla believes that a new vehicle roof design, comprised of different materials than the standard metallic or glass elements used in cars today, would allow the company to integrate modern vehicular technologies, “particularly those requiring radio frequency transmission and reception.

Instead of glass or metallic materials, Tesla says vehicles may benefit from high-strength polymer blends, such as Polycarbonate, Acrylonitrile Butadiene Styrene, or Acrylonitrile Styrene Acrylate.

These materials still provide ideal strength metrics for crashworthiness, stiffness for noise, vibration, and harshness control, and are compliant with head impact regulations.

They would also enable better performance with modern technologies, like internet terminals, which need an uninterrupted signal to satellites for maximum reception. Tesla writes in the patent:

“By employing polymer blends, some examples enable RF transmission from all the modules to satellites and other communication devices both inside and outside the vehicle.”

One of the challenges Tesla seems to be aware of with this type of roof design is the fact that it will still have to enable safety and keep that at the forefront of the design. As you can see in the illustration above, Tesla plans to use four layers to increase safety and rigidity, while also combating noise and vibration.

It notes in the patent that disclosed examples still meet the safety requirements outlined in the Federal Motor Vehicle Safety Standards (FMVSS).

Starlink integrated directly into Tesla vehicles would be a considerable advantage for owners. It would come with a handful of distinct advantages.

Initially, the inclusion of Starlink would completely eliminate cellular dead zones, something that is an issue, especially in rural areas. Starlink would provide connectivity in these remote regions and would ensure uninterrupted service during road trips and off-grid adventures.

It could also be a critical addition for Robotaxi, as it is crucial to have solid and reliable connectivity for remote monitoring and fleet management.

Starlink’s growing constellation, thanks to SpaceX’s routine and frequent launch schedule, will provide secure, stable, and reliable internet connectivity for Tesla vehicles.

SpaceX reaches incredible milestone with Starlink program

Although many owners have already mounted Starlink Mini dishes under their glass roofs for a similar experience, it may be integrated directly into Teslas in the coming years, either as an upgrade or a standard feature.

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Tesla supplements Holiday Update by sneaking in new Full Self-Driving version

It seems Tesla was waiting for the Hardware 4 rollout, as it wanted to also deploy a new Full Self-Driving version to those owners, as it appeared in the release notes for the Holiday Update last night.

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Credit: Tesla

Tesla has surprised some owners by sneaking in a new Full Self-Driving version with the wide release of the Holiday Update, which started rolling out to Hardware 4 owners on Friday night.

Tesla has issued a controlled and very slow release pattern with the Holiday Update, which rolls out with Software Version 2025.44.25.5.

For the past two weeks, as it has rolled out to Hardware 3 and older Tesla owners, the company has kept its deployment of the new Software Version relatively controlled.

It seems Tesla was waiting for the Hardware 4 rollout, as it wanted to also deploy a new Full Self-Driving version to those owners, as it appeared in the release notes for the Holiday Update last night.

Tesla Full Self-Driving v14.2.1.25 made its first appearance last night to Hardware 4 owners who are members of the Early Access Program (EAP). It appears to be a slight refinement from FSD v14.2.1, which has been out for a couple of weeks.

Many owners welcome the new FSD version, us included, because we’ve been less than impressed with v14.2.1. We have experienced some minor regressions with v14.2.1, especially with Speed Limit recognition, Speed Profile tinkering, and parking performance.

As it stands, Full Self-Driving is still particularly impressive, but Tesla is evidently having an issue with some of the adjustments, as it is still refining some of the performance aspects of the suite. This is expected and normal with some updates, as not all of them are an improvement in all areas; we routinely see some things backtrack every once in a while.

This new FSD version is likely to take care of those things, but it also includes all of the awesome Holiday Update features, which include:

  • Grok with Navigation Commands (Beta) – Grok will now add and edit destinations.
  • Tesla Photobooth – Take pictures inside your car using the cabin-facing camera
  • Dog Mode Live Activity – Check on your four-legged friend on your phone through periodic snapshots taken of the cabin
  • Dashcam Viewer Update – Includes new metrics, like steering wheel angle, speed, and more
  • Santa Mode – New graphics, trees, and a lock chime
  • Light Show Update – Addition of Jingle Rush light show
  • Custom Wraps and License Plates – Colorizer now allows you to customize your vehicle even further, with custom patterns, license plates, and tint
  • Navigation Improvements – Easier layout and setup
  • Supercharger Site Map – Starting at 18 pilot locations, a 3D view of the Supercharger you’re visiting will be available
  • Automatic Carpool Lane Routing – Navigation will utilize carpool lanes if enabled
  • Phone Left Behind Chime – Your car will now tell you if you left a phone inside
  • Charge Limit Per Location – Set a charge limit for each location
  • ISS Docking Simulator –  New game
  • Additional Improvements – Turn off wireless charging pad, Spotify improvements, Rainbow Rave Cave, Lock Sound TRON addition

Tesla also added two other things that were undocumented, like Charging Passport and information on USB drive storage to help with Dashcam.

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Tesla updates Cybertruck owners about key Powershare feature

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Credit: Tesla

Tesla is updating Cybertruck owners on its timeline of a massive feature that has yet to ship: Powershare with Powerwall.

Powershare is a bidirectional charging feature exclusive to Cybertruck, which allows the vehicle’s battery to act as a portable power source for homes, appliances, tools, other EVs, and more. It was announced in late 2023 as part of Tesla’s push into vehicle-to-everything energy sharing, and acting as a giant portable charger is the main advantage, as it can provide backup power during outages.

Cybertruck’s Powershare system supports both vehicle-to-load (V2L) and vehicle-to-home (V2H), making it flexible and well-rounded for a variety of applications.

However, even though the feature was promised with Cybertruck, it has yet to be shipped to vehicles. Tesla communicated with owners through email recently regarding Powershare with Powerwall, which essentially has the pickup act as an extended battery.

Powerwall discharge would be prioritized before tapping into the truck’s larger pack.

However, Tesla is still working on getting the feature out to owners, an email said:

“We’re writing to let you know that the Powershare with Powerwall feature is still in development and is now scheduled for release in mid-2026. 

This new release date gives us additional time to design and test this feature, ensuring its ability to communicate and optimize energy sharing between your vehicle and many configurations and generations of Powerwall. We are also using this time to develop additional Powershare features that will help us continue to accelerate the world’s transition to sustainable energy.”

Owners have expressed some real disappointment in Tesla’s continuous delays in releasing the feature, as it was expected to be released by late 2024, but now has been pushed back several times to mid-2026, according to the email.

Foundation Series Cybertruck buyers paid extra, expecting the feature to be rolled out with their vehicle upon pickup.

Cybertruck’s Lead Engineer, Wes Morrill, even commented on the holdup:

He said that “it turned out to be much harder than anticipated to make powershare work seamlessly with existing Powerwalls through existing wall connectors. Two grid-forming devices need to negotiate who will form and who will follow, depending on the state of charge of each, and they need to do this without a network and through multiple generations of hardware, and test and validate this process through rigorous certifications to ensure grid safety.”

It’s nice to see the transparency, but it is justified for some Cybertruck owners to feel like they’ve been bait-and-switched.

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