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SpaceX’s Falcon Heavy fairing tries to enter hyperspace, lands in net in new videos

SpaceX's first successful Falcon fairing catch was preceded by a spectacular light show as the fairing reentered Earth's atmosphere at hypersonic velocities. (SpaceX/Teslarati)

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SpaceX and CEO Elon Musk have released videos offering an extended look at the unexpectedly dramatic conditions Falcon payload fairings are subjected to during atmospheric reentry, as well as the first successful landing in GO Ms. Tree’s net.

Captured via an onboard GoPro camera during Falcon Heavy’s June 25th launch of the USAF Space Test Program-2 (STP-2) mission, the minute-long cut shows off a light show more indicative of a spacecraft entering hyperspace than the slightly more mundane reality. Shortly after SpaceX posted the reentry video, CEO Elon Musk followed up with a video showing a fairing’s gentle landing in Ms. Tree’s net. More likely than not, the fairing with the camera attached and the fairing that became the first to successfully land in Mr. Steven’s (now GO Ms. Tree’s) net are the same half. Regardless, the videos help document a major step forward towards SpaceX’s ultimate goal of fairing reuse.

“In a pleasant, last-minute surprise, SpaceX fairing recovery vessel Mr. Steven has departed Port Canaveral for its first Falcon fairing catch attempt in more than half a year. The speedy ship has already traveled more than 1250 km (800 mi) in ~48 hours and should soon be in position to attempt recovery of Falcon Heavy Flight 3’s payload fairing halves.

Over the last week or two, Mr. Steven has been officially renamed to GO Ms. Tree, a strong indicator that Guice Offshore (GO) – a company SpaceX is heavily involved with – has acquired the vessel from financially troubled owner/operator Sea-Tran Marine. With this likely acquisition, nearly all of SpaceX’s non-drone ship vessels are now leased from – and partially operated by – GO. The name change is undeniably bittersweet for those that have been following Mr. Steven’s fairing recovery journey from the beginning. However, it’s also more than a little fitting given that the vessel switched coasts and suffered an accident that forced SpaceX to replace the entirety of its arm-boom-net assembly. Much of Mr. Steven – now GO Ms. Tree – has been replaced in the last few months and with any luck, the vessel is better equipped than ever before to snag its first Falcon fairing(s) out of the air.”


— Teslarati.com, June 24th

As they say, the rest is history. Some 60-75 minutes after Falcon Heavy lifted off from Pad 39A on June 25th, Ms. Tree successfully caught a parasailing fairing for the first time ever, just barely snagging one of the two halves at the very edge of the ship’s net. Two days later, Ms. Tree arrived back at Port Canaveral. Another 24 hours after that, the intact, dry fairing half was safely lifted onto land and transported to a local SpaceX facility dedicated to analyzing (and eventually refurbishing) recovered Falcon fairings.

With any luck, the successful catch will prove that the years of work have been worth it, demonstrating that fairing halves caught – rather than fished out of the ocean – are structurally sound and clean enough to be quickly and affordably reused. While Falcon fairings have been estimated to take up less than 10% of the material cost of Falcon 9 production (~$6M, $3M/half), the manufacturing apparatus needed to build them takes up a huge amount of space. Additionally, the process of oven-curing huge, monolithic carbon fiber fairings introduces fundamental constraints that physically limit how quickly they can be built.

Fairing reuse would be an invaluable benefit for SpaceX’s internal Starlink launches, of which dozens and – eventually – hundreds will be needed to build an operational constellation of satellites. Thanks to the wonders of Falcon 9 Block 5 booster reuse, the internal cost of a flight-proven booster is essentially just the cost of refurbishment and then the propellant and work-hours needed to launch it. What remains is the cost of the expendable Falcon upper stage (unlikely to be recovered or reused) and payload fairing, now reasonably consistent at landing intact on the ocean surface but yet to demonstrate practical reusability.

As proposed, SpaceX’s completed Starlink constellation represents almost 12,000 satellites. Assuming no progress is made with packing density, no larger payload fairing is developed, and Starship doesn’t reach orbit until the mid-2020s (admittedly unlikely), Starlink will require almost exactly 200 Falcon 9 launches, each carrying 60 satellites. According to Musk, despite the fact that the first 60 satellites launched were effectively advanced prototypes, the cost of launch is already more than the cost of satellite production.

Speaking at a conference in 2017, Musk noted that payload fairings cost about $6M to produce, roughly 10% of Falcon 9’s $62M list price. In 2013, Musk stated that the first stage represented less than 75% of the overall cost of Falcon 9 production, meaning that the rocket’s upper stage probably represents another 15-20% (call it a 70:20:10 split), or ~$9-12M. Conservatively assuming that the operating costs of Falcon 9 refurbishment, launch, and recovery are roughly $5M per mission, the internal cost to SpaceX for a launch with a recoverable flight-proven booster and an expended fairing and upper stage could be just $20-25M and may be even lower.

A general overview of Starlink’s bus, launch stacking, and solar array. (SpaceX)
SpaceX’s first Starlink launch was also Falcon 9 booster B1049’s third launch ever.(SpaceX/Teslarati)

For reference, assuming 200 Falcon 9 launches, SpaceX could save nearly $600M by consistently recovering and reusing just one fairing half on average per launch, up to as much as $1.2B if both halves can be consistently recovered and reused. June 25th’s successful fairing catch is the biggest step yet in that direction and is hopefully a sign of many good things to come for SpaceX’s latest attempt at building truly reusable rockets.

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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 Optimus Gen 3 shows off a cleaner, factory-ready design in new app discovery

Renders hidden inside Tesla’s Android app show Optimus Gen 3’s design before any official reveal.

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla may have accidentally given a first look at its newest Optimus Gen 3 humanoid robot when photos were found in the Tesla smartphone app.

Design files tucked inside a recent Android version of the Tesla app appear to show the third generation humanoid robot next to the older Gen 2.5 prototype. The assets were extracted from the app package by Tesla community member @wholemars, who posted the renders on X late Tuesday night before deleting them. The Tesla Newswire reshared the side by side comparison on Wednesday, and the images have circulated widely since.

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

The files are labeled “gen3” and were built as models for Tesla app’s own interface, as validated directly by Grok to be official.

The comparison shows a robot that looks built for a factory line rather than a lab bench. Gen 2.5’s exposed mechanical linkages and gold plating on the knees and shins are gone. In their place, Gen 3 uses matte black fairings on the lower legs, paired with a more contoured champagne gold body. Flexible covers now seal the joint where the torso meets the upper thighs, keeping bearings and moving parts sealed from debris and unnecessary contact.

The body panels fit more tightly, and the hands, which Tesla has said carry 22 degrees of freedom, look far more refined than those on earlier units.

This most recent leak fills a gap Tesla has left open for most of the year. Elon Musk said on March 31 that Optimus 3 was walking around but needed “some finishing touches” before it could be shown, a delay Teslarati covered when Tesla missed its first quarter reveal target. Musk later said Tesla would hold the design back until closer to production, partly to keep competitors from copying it. No reveal date has been announced.

The app itself has been preparing for Optimus for months. In July, code in the Tesla app pointed to a dedicated robot phone key, a consent screen for collecting video and spatial data while Optimus works inside a home, and an alert system for low battery and mechanical faults. Finished 3D models of Gen 3 suggest the interface owners will eventually use is moving past placeholder code toward something Tesla intends to ship.

Manufacturing is moving in parallel. Tesla tore out the original Model S and Model X lines at Fremont this summer to make room for Optimus production, with a planned capacity of one million robots a year. At Giga Texas, the steel frame of a dedicated Optimus factory is nearing completion ahead of a targeted 2027 start, with Musk pointing to an eventual output of 10 million units annually.

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Tesla Semi lands the biggest electric truck deal in U.S. history

Tesla leads a record 2,500 truck order, but not every truck will be a Semi.

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Tesla has landed the largest electric truck order in U.S. history. ZET SCALE, a new alliance of shippers and carriers, named Tesla its primary manufacturer on Tuesday for an initial order of 2,500 electric Class 8 trucks. The deal alone would nearly double the number of electric heavy trucks operating in the country.

According to the press release from Catalyst Mobility, the nonprofit formerly known as CALSTART, Kenworth, RIDE and Volvo were also selected as secondary manufacturers that carriers can pick if their operations call for it. No split between the four brands has been published, so the exact number of Semis in the order is not yet known.

Tesla won the top slot through a competitive request for proposals. The alliance, which Catalyst Mobility runs with the Smart Freight Centre, scored bidders on price, range, charging capability and production capacity. Pooling freight demand from founding shippers, including Microsoft and PepsiCo, let every truck maker bid lower than it would for a single fleet. “The Tesla Semi is designed for lower cost per mile operations than diesel,” said Dan Priestley, director of the Tesla Semi program, as noted in the press release.

The financing is built to pull in carriers who have avoided electric trucks. ZET Financial is issuing the purchase order for all 2,500 units and will place them with fleets through a fair market value lease. The trucks will be deployed over the next few years across 10 freight hubs in Los Angeles, Stockton, Bakersfield, Seattle and Tacoma, Houston, Dallas, San Antonio, Chicago, Atlanta, and the Newark and New York area. ZET SCALE says the first order is only the opening round, with a longer term goal of 10,000 trucks or more.

Even if Tesla ends up with only a majority share, it would still be the biggest Semi deal to date. Einride’s 500 unit order in August was the previous record, and WattEV’s 370 truck order in May was the largest California deal at the time. Einride’s CEO has since said he expects all 500 trucks delivered by the end of 2027.

The announcement lands two days before Tesla formally inaugurates its Semi factory in Nevada on September 24. The 1.7 million square foot plant sits next to Gigafactory Nevada’s 4680 cell lines and is designed for 50,000 trucks a year.

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Tesla integrates Grok Bot into its vehicles for the ultimate personal assistant

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Credit: Grok

Tesla has expanded Grok from an in-car chatbot into a hands-free work assistant. On September 22, Tesla officially launched Grok Bot capability, confirming that drivers can now manage email, calendars, files, chats, and tasks by voice and then hand more ambitious errands to the AI-fueled productivity cheat code.

Grok itself is built by xAI. The new car features split into two layers: Connectors link Grok to outside accounts. Grok Bot, currently limited to SuperGrok Heavy subscribers, can complete multi-step tasks such as placing a usual coffee order, booking a reservation, or scheduling an appointment. It truly puts the driver in a nearly complete hands-free driving and productivity setting, with ironically the only task truly requiring your hands being to touch the “Start Self-Driving” button.

We were granted access to Grok Bot’s Tesla integration a few weeks back, and we’ve been able to do a handful of things with it. On a handful of occasions, we’ve used it to order food and have it ready for pickup slightly later into the evening; we’ve managed to pick up groceries after a day of errands with Grok Bot, and outside of the car, it’s helped with budgeting and even my fantasy football draft.

Tesla shows another way to utilize it: in their demo, a driver says “Hey Grok,” asks the assistant to check an inbox, and hears that a message concerns a weekend reservation. Grok then scans the calendar, reports no conflicts, and confirms the Tahoe trip is clear. It can also add check-in details to a road-trip itinerary. The point is not novelty chat. It is keeping eyes on the road, or on Full Self-Driving, while the car handles the paperwork of a trip:

This Grok rollout is not a gadget add-on as much as it is Tesla’s thesis in software form: the car should stop being a machine you operate and start being a room you occupy.

Connectors and Grok Bot treat the cabin as an office that happens to move, and that has truly been Tesla’s intention for years now. The car has slowly become an extension of a home more than a vehicle. Inbox, calendar, groceries, takeout, and reservations become voice work, not dashboard chores that you need to do before you get in your car.

Responsibility shifts from the driver to the stack, and as many Tesla owners rely on FSD for travel, Grok Bot now handles the monotony of dinner reservations or appointments.

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