News
SpaceX Falcon Heavy with Block 5 rockets targets November launch debut
According to several of its satellite passengers, SpaceX’s second launch of Falcon Heavy – this time with three Falcon 9 Block 5 boosters – is understood to be targeted for no earlier than November 2018 and will mark the first commercial mission for the world’s most powerful operational rocket.
Under the blanket label Space Test Program-2 (STP-2), Falcon Heavy’s first operational mission will be conducted for the US Air Force and see 25 various spacecraft – some weighing as much as 500 kilograms – launched into an equally varied selection of orbits, requiring a complex series of restarts and burns for the rocket’s upgraded Block 5 second stage. STP-2 also includes a huge 5000-kilogram ballast mass as a result of the decision to fly the mission as a demonstration of Falcon Heavy instead of a less powerful but cheaper and simpler single-booster Falcon 9. The total mass of all 25 payloads is likely far beneath the powerful rocket’s actual capabilities, as are the performance and propellant reserves required for the upper stage to inject different spacecraft into a number of orbits, hence the inclusion of so much dead mass.
Falcon 9 Block 5 shows off its interstage heat shielding and titanium grid fins. Falcon Heavy’s three boosters will likely look nearly identical. (Tom Cross)
Of those 25 distinct payloads, a number even include their own co-passenger satellites and experiments and have orbit requirements ranging from a basic circular low Earth orbit (~700km) to an odd, elliptical orbit with ends at 6000 and 12000km. For Falcon Heavy’s second flight, SpaceX will be fielding three highly reusable Block 5 boosters and a Block 5 upper stage with upgrades that enable the vehicle to operate far longer on orbit and reignite its Merlin Vacuum engine three or more times.
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- SpaceX’s second Falcon Heavy launch will either be the USAF’s STP-2, a collection of smaller satellites, or Arabsat 6A, a large communications satellite. (USAF)
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- One group of STP-2 passengers, known as DSX, has been awaiting launch for more than eight years. (USAF)
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- Falcon Heavy explodes off of Pad 39A in a spectacle of fire, Roadster in tow. (Tom Cross)
Unlikely to seriously tax Falcon Heavy’s brute-force payload lifting capabilities even with five metric tons of ballast, STP-2 will still be a lengthy and complicated endeavor for SpaceX’s Falcon upper stage – perhaps the most complex the company has yet to attempt. However, above all else, the most difficult aspect of the USAF STP-2 mission is almost certainly the comparatively mundane act of coordinating dozens of wildly different satellites and spacecraft from an equally varied number of different and geographically disparate institutions, companies, and government agencies, all of which must be ready for launch and attached to the same SpaceX payload adapter at roughly the same time to prevent mothballing launch delays.
RELATED: Reliving SpaceX Falcon Heavy: A press photographer’s memoir, not so much a blog post
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- Falcon Heavy as seen a day before launch, February 5. (Tom Cross)
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- All nine Merlin 1Ds displayed with their adorable cozies. (Tom Cross/Teslarati)
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- Falcon Heavy’s stunning dual side booster recovery. (SpaceX)
SpaceX’s first Falcon Heavy completed its spectacularly successful debut earlier this year with a mission that saw CEO Elon Musk’s own Tesla Roadster launch into orbit around the sun and culminated in the truly extraordinary near-simultaneous landings of the rocket’s two flight-proven side boosters. Those boosters both completed their first launches in 2016, nearly two years prior to their second and final flights, and the reinforced center core was built as a new but now-outdated Block 3, lessening the blow from its failure to land aboard the drone ship Of Course I Still Love You after separating from the upper stage. Like all Block 5 versions of Falcon, the second Falcon Heavy’s Block 5 boosters should be expected to support a number of launches before retirement, ranging from several to as many as 100.
News
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years.
The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Dry cathode 4680 cells
In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.
The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”
Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.
4680 packs for Model Y
Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla:
“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”
The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.
Elon Musk
Tesla Giga Texas to feature massive Optimus V4 production line
This suggests that while the first Optimus line will be set up in the Fremont Factory, the real ramp of Optimus’ production will happen in Giga Texas.
Tesla will build Optimus 4 in Giga Texas, and its production line will be massive. This was, at least, as per recent comments by CEO Elon Musk on social media platform X.
Optimus 4 production
In response to a post on X which expressed surprise that Optimus will be produced in California, Musk stated that “Optimus 4 will be built in Texas at much higher volume.” This suggests that while the first Optimus line will be set up in the Fremont Factory, and while the line itself will be capable of producing 1 million humanoid robots per year, the real ramp of Optimus’ production will happen in Giga Texas.
This was not the first time that Elon Musk shared his plans for Optimus’ production at Gigafactory Texas. During the 2025 Annual Shareholder Meeting, he stated that Giga Texas’ Optimus line will produce 10 million units of the humanoid robot per year. He did not, however, state at the time that Giga Texas would produce Optimus V4.
“So we’re going to launch on the fastest production ramp of any product of any large complex manufactured product ever, starting with building a one-million-unit production line in Fremont. And that’s Line one. And then a ten million unit per year production line here,” Musk stated.
How big Optimus could become
During Tesla’s Q4 and FY 2025 earnings call, Musk offered additional context on the potential of Optimus. While he stated that the ramp of Optimus’ production will be deliberate at first, the humanoid robot itself will have the potential to change the world.
“Optimus really will be a general-purpose robot that can learn by observing human behavior. You can demonstrate a task or verbally describe a task or show it a task. Even show it a video, it will be able to do that task. It’s going to be a very capable robot. I think long-term Optimus will have a very significant impact on the US GDP.
“It will actually move the needle on US GDP significantly. In conclusion, there are still many who doubt our ambitions for creating amazing abundance. We are confident it can be done, and we are making the right moves technologically to ensure that it does. Tesla, Inc. has never been a company to shy away from solving the hardest problems,” Musk stated.
Elon Musk
Rumored SpaceX-xAI merger gets apparent confirmation from Elon Musk
The comment follows reports that the rocket maker is weighing a transaction that could further consolidate Musk’s space and AI ventures.
Elon Musk appeared to confirm reports that SpaceX is exploring a potential merger with artificial intelligence startup xAI by responding positively to a post about the reported transaction on X.
Musk’s comment follows reports that the rocket maker is weighing a transaction that could further consolidate his space and AI ventures.
SpaceX xAI merger
As per a recent Reuters report, SpaceX has held discussions about merging with xAI, with the proposed structure potentially involving an exchange of xAI shares for SpaceX stock. The value, structure, and timing of any deal have not been finalized, and no agreement has been signed.
Musk appeared to acknowledge the report in a brief reply on X, responding “Yeah” to a post that described SpaceX as a future “Dyson Swarm company.” The comment references a Dyson Swarm, a sci-fi megastructure concept that consists of a massive network of satellites or structures that orbit a celestial body to harness its energy.
Reuters noted that two entities were formed in Nevada on January 21 to facilitate a potential transaction for the possible SpaceX-xAI merger. The discussions remain ongoing, and a transaction is not yet guaranteed, however.
AI and space infrastructure
A potential merger with xAI would align with Musk’s stated strategy of integrating artificial intelligence development with space-based systems. Musk has previously said that space-based infrastructure could support large-scale computing by leveraging continuous solar energy, an approach he has framed as economically scalable over time.
xAI already has operational ties to Musk’s other companies. The startup develops Grok, a large language model that holds a U.S. Department of Defense contract valued at up to $200 million. AI also plays a central role in SpaceX’s Starlink and Starshield satellite programs, which rely on automation and machine learning for network management and national security applications.
Musk has previously consolidated his businesses through share-based transactions, including Tesla’s acquisition of SolarCity in 2016 and xAI’s acquisition of X last year. Bloomberg has also claimed that Musk is considering a merger between SpaceX and Tesla in the future.
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
Tesla Giga Texas to feature massive Optimus V4 production line
