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SpaceX Starlink launch suffers third weather scrub, next attempt Tuesday

SpaceX is headed for its third Starlink-12 launch attempt after ~20 days of delays. (SpaceX)

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Update: Multiple weather constraint violations forced SpaceX to scrub today’s Starlink-12 launch attempt less than half an hour before liftoff, marking the mission’s third weather-related scrub and fourth abort overall since mid-September. As of October 4th, the US Air Force 45th Space Wing predicted a 40% chance of weather violation.

SpaceX’s fifth Starlink-12 launch attempt is scheduled no earlier than 7:29 am EDT (11:29 UTC) on Tuesday, October 6th. The mission-specific T-1 weather forecast predicts a 70% chance of favorable conditions.

On the heels of a rare last-second Falcon 9 launch abort, SpaceX is closing in on its third attempt to launch the 12th batch of operational Starlink satellites.

Scheduled to lift off from Kennedy Space Center (KSC) Launch Complex 39A (Pad 39A) no earlier than (NET) 7:51 am EDT (11:51 UTC) on Monday, October 5th, Starlink-12 was originally scheduled to launch in mid-September. Bad weather at the Atlantic Ocean landing zone caused a ten-day delay from September 17th to the 27th, followed by a pad weather delay on the 28th.

After a ULA Delta IV Heavy mission with range priority was scrubbed for the seventh time on September 30th, SpaceX tried to launch Starlink-12 again but suffered an abort – later blamed on a pad sensor – seven seconds before liftoff. Finally, a new Falcon 9 launch with an upgraded GPS III satellite aboard was aborted just two seconds before liftoff on October 2nd. Moved from NET October 3rd to the 5th just prior to GPS III SV04’s separate launch delay, Starlink-12 is now up next.

Interrupting what has otherwise been a much-improved level of launch readiness and schedule reliability for Falcon 9 and Falcon Heavy’s Block 5 upgrade, this recent string of delays – while mostly the result of weather and ULA’s own NROL-44 launch delays – has even become a concern for CEO Elon Musk. Currently focused on building out SpaceX’s new Starship factory and pushing towards the rocket’s first high-altitude and orbital test flights in Boca Chica, Texas, Musk stated that he would be flying to Cape Canaveral “to review hardware in person” on the week of October 5th.

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Musk also says that SpaceX is “doing a broad review of launch site, propulsion, structures, avionics, range, & regulatory constraints” to determine if an apparent goal of “48 launches” in 2021 is feasible.

To be fair to SpaceX, most of the plague of delays suffered by the company in the last month has been caused by a mixture of weather and the range’s preferential treatment of ULA’s “national security” NROL-44 launch. Additionally, of an impressive seven ULA NROL-44 launch attempts between August 26th and September 30th, just a single one was caused by weather – the remaining six a result of a wide variety of technical software and hardware bugs. SpaceX’s Starlink-12 and GPS III SV04 missions have only suffered one technical launch abort each on September 30th and October 2nd.

In other words, short of upgrading Falcon rockets to launch and land in worse weather conditions, most of SpaceX’s delays have been largely out of the company’s control, while ULA’s NROL-44 struggles demonstrate just how much worse things could be. According to an unofficial analysis of 44 Falcon Block 5 launches since May 2018, only four technical launch aborts have been triggered by a booster fault. Pad-caused aborts have been roughly as common, meaning that 1 in roughly 6 to 8 SpaceX launches suffers some kind of abort shortly before liftoff, on average.

Both captured in one frame, SpaceX’s GPS III SV04 and Starlink-12 missions have run into repeated launch delays over the last 1-3 weeks. (SpaceX)

Altogether, Falcon Block 5 rockets have been relatively dependable for on-time, on-schedule launches even if SpaceX has struggled with more repeated delays than usual in the last few months. To achieve anywhere close to 48 launches annually, however, major improvements will need to be made, likely including upgrades to whatever is responsible for Falcon 9’s weather constraints. As of October 2020, SpaceX has never launched four times in one month (or four times in the same ~30-day period). To launch 48 times in one year, SpaceX will need to average four launches per month. That, of course, in no way accounts for the possibility that 2020-esque summer weather could functionally cut 4-8+ weeks off of Falcon 9’s annual availability.

Regardless, SpaceX will begin live coverage of the third Starlink-12 launch attempt around 7:35 am EDT (11:35 UTC). Tune in to (hopefully) catch the company’s 17th launch this year.

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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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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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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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