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SpaceX Falcon boosters likely to surpass Elon Musk’s prime rocket reuse directive

SpaceX Falcon 9 booster B1051 is likely just several weeks away from its ninth launch, potentially guaranteeing a tenth flight before the second half of 2021. (Richard Angle)

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A SpaceX vice president and one of Elon Musk’s first hires says that Falcon boosters will soon meet – and should ultimately beat – the CEO’s longstanding target for rocket reusability.

Years before SpaceX began regularly landing and reusing orbital-class Falcon 9 and Falcon Heavy boosters, Musk was fairly consistent in stating that a primary goal of the ambitious program (then routinely belittled by most involved in aerospace) was to develop a rocket with a lifespan of at least ten launches. When the current and most reusable iteration of Falcon rockets (Block 5) debuted in May 2018, he went even further, stating that SpaceX’s goal was to reuse Block 5 boosters 10 times with minimal refurbishment but ultimately fly them a hundred or more times with intermittent overhauls.

According to SpaceX Vice President of Mission Assurance Hans Koenigsmann, soon to retire (or already retired) after almost two decades with the company, there are no obvious showstoppers that could prevent reusable Falcon boosters from soaring past Musk’s ten-flight target. Speaking at the 47th Spaceport Summit (formerly Space Congress) on February 23rd, Koenigsmann stated (in his opinion) that “ten is [not] a magic number.”

Fleet leader Falcon 9 booster B1051 could be matched by B1049 as early as February 28th, leaving SpaceX with two eight-flight rockets before the end of Q1 2021. (Richard Angle)

“Until [SpaceX sees] more damage” showing up on recovered fleet-leading rockets, the former VP thinks that there is nothing fundamentally preventing Falcon boosters from flying more than ten times each. In other words, the fairly arbitrary ten-flight goalpost set by CEO Elon Musk years ago may ultimately be quite accurate, resulting in an operational fleet of rockets nominally capable of achieving that target – and then some.

Of course, the question of whether a Falcon booster can launch ten or more times is made irrelevant if SpaceX can’t simultaneously ensure that booster recovery is at least as reliable as the Block 5 design is sturdy. That fundamental challenge reared its head on February 15th when Falcon 9 booster B1059 – on its sixth flight – failed shortly before landing for unknown reasons. On the same conference panel, Koenigsmann couldn’t add much detail to the nonexistent public record, only offering the unfortunate euphemism that the rocket failed because of “heat damage.”

Indeed, SpaceX’s official webcast – and some solid unofficial analysis of available data – does suggest that Falcon 9 was traveling a bit faster (and thus receiving a bit more heat) than planned. But the so-called “heat damage” that may have destroyed the rocket is just a symptom of some other unmentioned trigger – be it incorrect angle of attack, bad avionics sensors, engine underperformance, or any number of other possible causes.

Either way, SpaceX is hoping for a quick return to flight after the booster landing failure. Pending the completion of Starlink-19’s anomaly investigation, its next two Starlink launches have been rescheduled on February 28th and March 7th, representing just a one or two-week delay.

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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 Semi catches fire in California: what we know

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Credit: KTVU

A Tesla Semi caught fire in Hayward, California, which caused both directions of traffic to shut down for hours before being completely reopened early on Wednesday, the California Highway Patrol said.

The fire occurred just after 5:30 local time in Hayward on Tuesday, as the Semi caught fire in the southbound lanes of I-880 before CHP officials made the decision to shut down both lanes of traffic due to potential risks from hazardous chemical smoke.

There were no injuries reported.

The cause of the fire is currently unknown, as neither Tesla nor the CHP have not determined a cause.

However, some images taken before the Semi was completely destroyed by the fire seem to indicate this might have been an older unit, as it appears to be one of the designs that Tesla shipped as part of its pilot program, before revising it and starting mass production just a month ago.

At the time of publication, CHP had not returned our request for a comment for additional details, including the Semi involved and any potential collaboration on an investigation between the CHP and Tesla. We will update this story when we hear back from them.

The southbound lanes were reopened at 3:30 a.m. on Wednesday, with the northbound lanes opening last night a few hours after the fire began. The CHP did state that the lithium batteries were “incredibly difficult to extinguish,” according to NBC Bay Area.

The truck’s driver said that the Semi caught fire, but he did not have an explanation.

An estimated 5,000 to 7,000 semi-truck and large commercial vehicle fires occur on U.S. roadways every year.

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Tesla’s ‘Emergency Drive Away’ function gets its first use in the real world

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Credit: Tesla

Tesla’s launch of the “Emergency Drive Away” function a few months back offered owners a safe option to evacuate an area if they were in reasonable danger. The function finally got its first use in the real world, but it appears it was by mistake.

A video shared by u/Joshalander in the r/TeslaLounge subreddit recorded the instance from his vehicle and said the incident took place in Austin this past weekend during the city’s F1 Race.

“Was charging around 6 AM this past Sunday in Austin before heading to the F1 race and heard a pop. Looked over and saw the new emergency drive-away feature in action. Genuinely felt bad for the dude when he got out and realized what happened, since he looked exhausted and only seemed to half-read the prompts.”

Emergency Drive Away unlatches the Supercharger connector from the vehicle, but still causes damage to both the car and the Supercharger. Tesla has said that it will cost up to $25,000 in repairs to have everything fixed back to normal.

Additionally, the company said that if it were not used in an emergency situation, the driver of the vehicle who activated the Emergency Drive Away feature would be responsible for all repair costs.

Tesla constitutes the following situations as reasonable justifications for activating the feature:

  • You face an immediate threat to your life or personal safety.
  • You must leave the area immediately.
  • Exiting the vehicle is unsafe.
  • Unplugging the charge connector would unreasonably delay your departure or expose you to a risk to your personal safety.

After using the feature, Tesla requires the driver to schedule Service so the car can be inspected.

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Tesla’s Cybercab battery design could make robotaxis even cheaper

Tesla built the Cybercab’s battery pack with spare room for a future switch to LFP.

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Tesla built the Cybercab’s battery pack with empty space inside it on purpose, and the reason points to a cheaper robotaxi down the road.

Robert Sumpf, Tesla’s director of mechanical design engineering for battery modules and packs, said the extra room beside and beneath the Cybercab’s modules was left there so the company can move to lithium iron phosphate cells later. “So, we protected this pack to go to an even lower energy dense chemistry as we scale and need to bring LFP into the platform,” Sumpf said in a Cybercab deep dive with Munro Live.

The Cybercab runs on Tesla’s own 4680 cells with a nickel chemistry today. LFP cells store less energy for their size, so a straight swap would cut range. The reserved space lets Tesla add more LFP cells to make up the difference. In return, Tesla would get cells that cost less, run cooler and survive more charge cycles. LFP became the most used EV battery chemistry in the world last year.

Not all of that room was planned for a chemistry change. Lars Moravy, Tesla’s Vice President of Vehicle Engineering, said part of it exists because “we didn’t need as many batteries as we thought we did.” Tesla told Sandy Munro in early 2025 that it was targeting a Cybercab pack under 50 kWh with close to 300 miles of range.

The pack also breaks from the structural design Tesla used in some Model Y and Cybertruck builds. Instead of potting hundreds of cells into one block, the Cybercab uses four separate, individually sealed modules, so a bad module can be replaced without scrapping the whole pack. Sumpf was blunt about the older approach, giving the Model Y structural battery “a grade D” because it was hard to build and nearly impossible to repair. He estimated a fully structural pack gains about 10% more cell volume, but said “the issue is the service cost.”

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That cost matters more for a car that rarely sits parked. Cybercab chief engineer Eric Earley said replacing an entire pack “before half a million miles is a killer on cost,” which is why remanufacturing and serviceability were built into the design from the start.

The same Munro Live tour produced Moravy’s admission that the Cybercab line at Giga Texas is now outpacing Robotaxi deployments, along with a look at the robotaxi’s unorthodox paint process. Tesla is aiming to deliver the first Cybercabs to outside customers by the end of 2026, though Elon Musk has said the vast majority will stay owned by Tesla and run as a transport service.

Sumpf did not give a date for an LFP version, name a cell supplier or say how a chemistry change would affect range. For now, the 4680 cars keep piling up: Texas DMV records from Tuesday list 544 Cybercabs authorized for Tesla’s Robotaxi fleet, more than the 507 Model Ys on the same roster for the first time.

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