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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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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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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.

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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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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.

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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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SpaceX’s next Starship launch is about to attempt its biggest leap yet

SpaceX targets September 22 for Starship Flight 14, its first attempt to reach real orbit.

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SpaceX has set September 22 as the target date for Starship’s 14th test flight, and this one carries a different goal than any of the 13 that came before it. Every previous Starship mission has intentionally flown a suborbital arc, reentering the atmosphere within the same hour it launched. Flight 14 is designed to send the craft into a genuine orbit around Earth for the first time.

The launch window opens at 7:15 a.m. Central time at Starbase in South Texas and runs for 75 minutes, pending regulatory approval, according to SpaceX’s mission description published Tuesday. If the flight goes as planned, Starship will circle the planet roughly six times at an altitude near 275 kilometers over about ten hours before a deorbit burn sends it toward a splashdown in the Pacific Ocean west of Chile, a departure from the Indian Ocean recoveries used on the last several flights.

The mission also marks the first attempt to put a working batch of Starlink V3 satellites into actual service. Flight 13 carried 20 of the new satellites in July, but because that mission never left a suborbital trajectory, the payload reentered along with the ship instead of separating into orbit.

SpaceX tells the FCC that Starship Flight 14 is going to orbit

Each V3 satellite is rated for roughly one terabit per second of downlink capacity, so a successful deployment on Flight 14 would be SpaceX’s largest single jump in network bandwidth since Starlink began flying on Falcon 9.

Flight 13 still did the heavier lifting on the technical side. That July mission flew a deliberately more stressful reentry profile to test Starship’s heat shield, and the ship survived its softest splashdown yet, intact enough for drone inspections shortly after landing. Elon Musk said the flight delivered “all the heat shield data we needed and then some,” a result Teslarati covered in detail when he later said SpaceX had solved the vehicle’s biggest reusability challenge. Flight 14 is where SpaceX starts spending that confidence on an actual orbital insertion rather than another controlled fall back to Earth.

One thing Flight 14 will not attempt is a tower catch of the ship. Musk floated the idea right after Flight 13, but walked the timeline back in August, saying a catch attempt was more likely “in a few months.” The Super Heavy booster will still aim for its own recovery, targeting an offshore landing point in the Gulf of America, the same approach used on recent flights.

September 22 is SpaceX’s own target, not a locked date. Starship’s schedule has slipped before over hardware readiness and FAA sign off, and the company has said as much in its own mission notes. But the plan itself represents the clearest marker yet that Starship is moving from a suborbital test program into something meant to carry paying payloads and, eventually, people.

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