SpaceX
SpaceX to launch replacement satellite two years after fateful Falcon 9 failure
On September 1st, 2016, SpaceX’s Falcon 9 rocket suffered a catastrophic anomaly during a static fire test, causing an explosion that completely destroyed the vehicle, the launch pad, and Spacecom’s $200M Amos-6 satellite. This ultimately triggered a months-long investigation into what CEO Elon Musk described as “the most difficult and complex failure [SpaceX has] had in 14 years.”
More than two years and 41 successful consecutive launches later, SpaceX and Israeli satellite operator Spacecom are reportedly aiming to launch Amos-6’s replacement – Amos-17 – as early as the end of May, around three months from now.
Business in Brief: Spacecom says it will launch Amos 17 satellite within four months https://t.co/nkIFd7DzHJ
— Haaretz.com (@haaretzcom) February 25, 2019
Nearly two and a half years distant, the reverberations of SpaceX’s Amos-6 Falcon 9 failure continue to reverberate loudly. Aside from demanding changes to the operational procedures used to launch Falcon 9 and forcing an extensive critical analysis of design, production, and qualification methods, SpaceX has spent countless resources pursuing an extensive redesign of the component pointed at as the primary source of the explosion that destroyed Falcon 9. Known as composite overwrapped pressure vessels (COPVs), SpaceX uses the bottles to store extremely high-pressure helium (5000+ psi, 340+ bar) to pressurize Falcon 9’s RP-1 and oxygen tanks, as well as nitrogen to power its cold-gas maneuvering thrusters.
According to a failure analysis performed by SpaceX with NASA, the USAF, the NTSB, and the FAA, it was concluded that the cause could be traced back to a complex series of events centered around those helium COPVs. Meant to be the first mission to utilize subcooled propellant and oxidizer, the extreme cold in the upper stage LOx tank caused solid oxygen to form on the outside of the COPVs located inside it. While complex, the gist was that liquid (and perhaps solid) oxygen could have formed around the outside of the COPV, potentially finding its way in between the carbon fiber wrappings, creating a buckle in the fibers, and ultimately causing fibers to break. Near the end of this process, those breaking fibers could have created a spark or breached the helium tank, instantaneously overpressurizing the upper stage and causing an explosion.
NASA’s Aerospace Safety Advisory Panel (ASAP) and NASA itself have aired concerns about those COPVs since 2016, triggering an extraordinarily comprehensive program of testing, characterization, and redesign of the COPVs SpaceX uses. They have now successfully flown on 3-4 Falcon 9 launches under the same expedited propellant loading conditions that an identical rocket will undergo in preparation for Crew Dragon launches. CEO Elon Musk spent several minutes discussing the redesigned COPVs in a May 2018 press conference and did not mince words when he described them as “by far the most advanced pressure vessel[s] ever developed by humanity.”
“The amount of testing and research that’s gone into COPV safety is gigantic. This is by far the most advanced pressure vessel ever developed by humanity. It’s nuts. And I’ve personally gone over the test design, I’ve lost count how many times. But the top engineering minds at SpaceX have agonized over this. We’ve tested the living daylights out of it. We’ve been in deep, deep discussions with NASA about this. And I think we’re in a good situation.” – SpaceX CEO Elon Musk, May 2018
NASA and ASAP concerns have since been alleviated, culminating on February 22nd with an official announcement that NASA was ready for SpaceX to conduct the first uncrewed launch of its Crew Dragon spacecraft on March 2nd. It’s thus almost poetic that customer Spacecom chose the same week to announce a target date for the Falcon 9 launch of a satellite built to replace the destroyed Amos-6, known as Amos-17. Soon after the Amos-6 disaster, Spacecom settled on a free SpaceX launch contract for a future satellite instead of an immediate $50M payout. Procured for around $160M, SpaceX is reportedly targeting the launch of the Boeing-built satellite during the week of May 27th, likely from Launch Complex 40 (LC-40) – the same pad that suffered extensive damage during the September 2016 anomaly.
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- Spacecom’s Boeing-built Amos-17 satellite. (Boeing)
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- Falcon 9 shows off some of its COPVs in a tour of SpaceX’s Hawthorne factory. (SpaceX)
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- An impressive view of Crew Dragon (DM-1), Falcon 9 B1051, and its upper stage. (SpaceX)
Since Amos-6, SpaceX’s record of reliability has been effectively spotless and now stands at an impressive 41 consecutive successful launches, including Falcon Heavy’s February 2018 debut. Aside from the sheer volume of launches SpaceX performed in a little over two years, the company has pushed full speed ahead towards its goal of routinely reusing Falcon 9 boosters. Less than 24 months after the first commercial reuse, SpaceX has landed Falcon 9 boosters 34 times and reused them 20 times, numbers that are only likely to grow in 2019.
Set to occur shortly after the planned launch debuts of Crew Dragon and Falcon Heavy (commercially), SpaceX will hopefully be able to place Amos-17 in a healthy orbit and thus effectively retire the Amos-6 saga before the second half of 2019.
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News
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.
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.
We’re excited for Falcon 9 and Dragon to launch @NASA’s Crew-15, 16, and 17 missions to the @Space_Station from Florida https://t.co/Qm16vVK9F3 pic.twitter.com/drg3s7GtuM
— SpaceX (@SpaceX) September 18, 2026
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.
Investor's Corner
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.
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.
The Giga Texas Optimus Factory latest update … construction keeps moving fast!
Steel assembly is now only about 5 column grids from the north perimeter beam. Concrete is going in on the three upper floors, rebar is still being laid for more pours, and footing / grade-beam work… pic.twitter.com/qvFPvwnYzW
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) September 17, 2026
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.
Investor's Corner
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.
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.
NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded
New drone video shows Tesla’s Optimus Factory reaching a turning point
