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SpaceX’s first Falcon Heavy launch in two years is finally coming together

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For the first time in more than two years, SpaceX’s next Falcon Heavy launch and dual-booster landing appears to be right around the corner – and it comes with a catch.

In February 2018, after years of anticipation, SpaceX successfully launched its triple-booster Falcon Heavy rocket for the first time in a spectacular show of force. Though the ‘center core’ booster got a little melty on its extremely high-speed reentry and was lost before it could attempt to land, the rocket’s twin side boosters performed an iconic near-simultaneous landing just a handful of miles away from where they lifted off.

Then Falcon Heavy took a good, long break. Ultimately, it would turn out that the debut vehicle was effectively a one-off and over the course of 14 months, SpaceX fairly quickly designed, built, and qualified an entirely new Falcon Heavy rocket based on Falcon 9’s new and improved Block 5 variant. In April 2019, after a few minor delays, that Falcon Heavy Block 5 rocket completed its own launch debut and first mission for a paying customer. This time around, all three boosters – two by land and one by sea – survived reentry and performed flawless landings on a drone ship and two Landing Zones.

A mere two months later, both of Falcon Heavy Block 5’s first two recovered side boosters flew again in support of the US Air Force’s STP-2 mission – a combined demonstration flight and rideshare mostly designed to push the rocket to its limits and help the military qualify it for high-value payloads. Once more, those side boosters successfully returned for a simultaneous landing at SpaceX’s Landing Zones but the mission’s Block 5 center core’s reentry was – as SpaceX itself partially expected – too hot, burning essential components and resulting in a hard ‘landing’ in the Atlantic Ocean. Otherwise, the mission was a spectacular success and gave the US military practically all the data it needed to qualify the world’s largest operational rocket to launch its payloads.

Shockingly, however, that June 2019 launch would end up being Falcon Heavy’s third and latest. In the almost 26 months since, the rocket hasn’t flown once. Originally scheduled to launch a fourth time as early as Q4 2020, the COVID-19 pandemic ultimately delayed the rocket’s next two launches (or gave the satellite manufacturer(s) perfect scapegoats for technical delays) into 2021.

Known as USSF-44 and USSF-52 (formerly AFSPC-44/52), both missions are scheduled to launch ethereal US military spy and/or communications satellites. USSF-44 is arguably the most important, as it will mark SpaceX’s first direct launch to geostationary orbit (GEO) for any customer – let alone one as exacting as the US military. USSF-52 is a much simpler and more traditional launch to an elliptical geostationary transfer orbit (GTO).

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About a year ago, for unknown reasons, the two missions swapped positions, with USSF-44 taking the lead. Expected to launch in June 2021 as of early this year, SpaceflightNow first reported that USSF-44 had slipped further still to October – and USSF-52 into 2022 – this May. Since then, that’s where the mission’s schedule has tentatively lain.

Finally, on August 12th, SpaceX filed an FCC application for rocket communication permissions. While otherwise ordinary, this particular request stated that it was for Falcon Heavy recovery operations and, more specifically, for the simultaneous recovery of two Falcon Heavy boosters at sea. Out of an abundance of caution and conservatism and combined with the generally challenging nature of direct-to-GEO launches, Falcon Heavy’s first such mission for the US military will require SpaceX to expend the rocket’s center booster and recover both side boosters at sea with two separate drone ships.

Falcon Heavy’s USSF-52 GTO launch isn’t as demanding and its mission profile is expected to allow SpaceX to recover all three boosters. As such, an FCC filing for a dual-drone-ship Falcon Heavy side booster recoveries practically guarantees that it’s for USSF-44. Per the application, SpaceX expects the mission to occur no earlier than September 25th. Almost simultaneously, launch photographer Ben Cooper also updated a long-running list of upcoming East Coast launches, confirming that Falcon Heavy’s fourth launch (USSF-44) remains on track for October 2021.

Ultimately, while delays are possible and likely probable, there now appears to be a strong chance that Falcon Heavy will launch for the first time in 28 months before the end of 2021.

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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