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SpaceX snags second Falcon 9 booster in two weeks after Crew Dragon launch

Falcon 9 B1051 returned to Port Canaveral for the first time aboard drone ship Of Course I Still Love You on March 5th. (Pauline Acalin)

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7 years ago

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SpaceX and the company’s drone ship Of Course I Still Love You (OCISLY) have successfully wrapped up their second Falcon 9 recovery in less than two weeks, bringing booster B1051 back to Port Canaveral to be broken over and refurbished for a second launch.

Following its support of Crew Dragon’s thus far flawless launch debut, the booster will likely be exceptionally easy to turn around for its next flight. That second launch could occur as early as late April for Cargo Dragon’s 17th mission, a consequence of NASA’s desire to keep its SpaceX missions on boosters that are ‘in family‘ (i.e. only new boosters or flight-proven boosters that have only launched NASA payloads).

https://twitter.com/_TomCross_/status/1102944003358687232

Although B1051’s reentry profile was relatively slow and gentle with main engine cut-off (MECO) and booster separation occurring at ~1.9 km/s (4250 mph) and 85 km (53 mi), its recovery was made intriguingly difficult by high seas at drone ship OCISLY’s Atlantic Ocean station. These bad conditions were readily visible at several points during SpaceX’s DM-1 livestream, with OCISLY heeling several degrees as the Falcon 9 booster’s Merlin 1D engine lit up the surrounding area like a floodlight. In fact, B1051’s post-landing struggle could actually be seen live as the booster clearly slide several meters across the drone ship’s deck almost immediately after touching down.

This issue of boosters sliding about and generally being difficult to deal with is actually one of the leading motivations that lead to SpaceX developing Octagrabber, a tank-like robot used to remotely secure recovery Falcon 9 first stages while minimizing the risk to the recovery team. In a situation like DM-1, with B1051 already sliding around OCISLY’s deck immediately after a night landing, Octagrabber would nominally be remotely activated and controlled, crawling from its garage to grab Falcon 9’s hold-down clamps and secure the stage with its own weight.

It’s actually unclear whether Octagrabber is capable of this sort of remote operation without SpaceX technicians aboard OCISLY, nor if SpaceX – as of late – has even tried to attempt to secure Falcon 9 boosters at night. The process of transferring crew between ships in heavy seas is actually quite dangerous on its own, so it would be less than surprising to hear that SpaceX’s recovery managers have cut down on nighttime operations in bad weather if Octagrabber can only be operated with crew present on OCISLY. For B1051, the drone ship, a tugboat, and crew boat GO Quest remained in the vicinity of the landing target until the following morning (still March 2nd) before beginning the ~500 km (~300 mi) trek back to Port Canaveral. Greeted by moody low-hanging clouds and scattered showers, observers were actually able to capture the rare sight – as pictured above – of Octagrabber being driven back into its blast shield/garage.

Regardless, future Commercial Crew launches – aside, perhaps, from SpaceX’s second demonstration launch (DM-2) later this year – will likely be able perform return-to-launch-site (RTLS) landings at the company’s Florida landing zones, much like Falcon 9 boosters already do after Cargo Dragon (CRS) missions. According to VP of Mission Assurance Hans Koenigsmann, B1051 had to conduct a drone ship (ASDS) recovery at sea due to NASA’s desire for conservative performance reserves to guard against the potential (and extremely unlikely) failure of one or several Merlin engines during the launch’s boost stage. In 2012, Falcon 9 suffered its first and only (known) in-flight Merlin failure, an anomaly which the rocket’s autonomously avionics perfectly dealt with to save the primary mission (Cargo Dragon’s operational debut, CRS-1). A secondary Orbcomm communications satellite sadly failed to make it to its operational orbit, however, classifying the mission as a partial failure. More recently, there have been unconfirmed hints pointing to other potential in-flight Merlin 1D failures, albeit during booster recovery attempts instead of the main boost phase. Whether or not those anomalies actually occurred, NASA is clearly all about extreme conservatism and ‘safety first’ approaches for the Commercial Crew Program (or at least SpaceX’s side of it).

SpaceX’s successful recovery of B1051 marks the company’s third launch and landing of 2019, thus far averaging a relatively slow one mission per month. While schedules can change, it currently appears that Crew Dragon’s DM-1 orbital debut will be the only SpaceX launch in March, barring Falcon Heavy’s own commercial debut occurring in the last few days of the month. According to a SpaceX representative speaking earlier this year, the company is actually aiming to equal or even surpass its 2018 record – 21 launches – in 2019, requiring a minimum average of two launches per month for the remainder of the year.

Numbers aside, SpaceX’s 2019 calendar will undoubtedly aim to surpass the number of major company milestones in a single year, a hard act to follow after 2017 and 2018. Ranging from the first operational Starlink satellite launches and the first SpaceX launch with astronauts aboard to major flight test and developmental milestones for the company’s next-gen Starship spaceship and Super Heavy booster, there are an incredible wealth of events to look forward to.

Check out Teslarati’s newsletters for prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket launch and recovery processes

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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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Elon Musk

Tesla’s mysterious Robovan makes a sneak peek with Optimus in Terafab video

Elon Musk shared a new Terafab video showing Optimus, Robovans, and a stunningly futuristic campus.

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1 hour ago

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August 6, 2026

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SpaceX Terafab rendering

Elon Musk posted a new video of Terafab on X Thursday morning, and the most eye-catching details in it were not the building itself, but two products still awaiting production: Optimus and the Robovan.

The concept render, credited to SpaceX, shows Optimus robots working the grounds of the roughly 2.5-mile-long facility planned for the Gibbons Creek site in Grimes County, while a Robovan glides along an elevated roadway cutting through the building itself, sharing the frame with a Tesla Semi and a Cybercab.

Robovan is the boxy, driverless people and cargo mover Musk unveiled alongside Cybercab at Tesla’s “We, Robot” event in October 2024. He pitched it as a way to move up to 20 passengers at once, or handle freight instead, at a target cost he claimed could fall under a dollar a mile, with no steering wheel or pedals, the same layout as Cybercab. Nearly two years later, Robovan still has no confirmed production timeline and has not shown up in any factory footage, which makes Thursday’s render one of the only recent looks at the vehicle in any form.

Optimus has moved further along. Tesla began converting Fremont’s old Model S and Model X assembly line into a Gen 3 Optimus production line earlier this year, and Musk visited the site on July 1 to mark the changeover. A second, larger Optimus plant is under construction at Giga Texas, targeting volume production in summer 2027 and eventual capacity of 10 million units a year. Tesla AI lead Ashok Elluswamy said this month the robot has “big shoes to fill” in replacing the S and X line, while Musk has repeatedly called Optimus the company’s biggest product of any kind, with a long-term price he has pegged between $20,000 and $30,000.


“Terafab Texas will be the largest and most valuable building on Earth by far,” Musk wrote alongside the clip. “And it will be stunningly beautiful.”

One quote post summed up the reaction: “Futuristic scene with RoboVan + Cybercab + Tesla Semi + Optimus.”

Beyond the vehicles, the architecture wrapped around them stands out too. The building’s facade is canted at sharp angles, with illuminated horizontal bands running through what appears to be a multi level interior visible from outside. Below the elevated roadway, pedestrians walk along a plaza next to a reflecting pool, and the skyline behind the campus is dotted with angular spires that read more like sculpture than infrastructure, a departure from the strictly utilitarian look of Gigafactory Texas or Starbase.

The timing tracks with what Terafab representative Riley Trennell told Grimes County residents on Wednesday, when he said renderings of the facility would be released “within days.” Musk’s post followed less than 24 hours later, and Texas Governor Greg Abbott’s office sent out its own release Thursday confirming the project. As Teslarati reported this morning, Terafab’s tax abatement agreements with Grimes County are now signed and active, and SpaceX has sent the county its first $10 million payment under that deal. The dollar figure tied to this phase of construction, per Reuters, is $16.8 billion, one of the first hard capital expenditure numbers attached to Terafab since Musk unveiled the joint Tesla-SpaceX-xAI venture in March.Reaction on X ranged from enthusiastic to skeptical. “God Bless Texas! Everything is bigger and better in Texas!” one reply read. Another was more measured: “Terafab in a decade…..”

Whether the finished building matches the render is a separate question from whether Musk wanted people talking about the render itself. Less than a day after posting, the video had already crossed 5.5 million views.

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Elon Musk

Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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August 5, 2026

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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Elon Musk

SpaceX has solved Starship’s biggest challenge, Elon Musk says

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1 day ago

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August 5, 2026

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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