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SpaceX’s next Falcon Heavy begins to arrive at 39A as center core heads to TX

Falcon Heavy just prior to its first fully-integrated static fire. (SpaceX)

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Approximately a week after a Falcon Heavy side booster – the first of two – arrived at SpaceX’s LC-39A launch complex, a sign of late-stage preparation for the massive rocket’s second and third launches, a Falcon Heavy center stage was spotted rolling through the Waco, Texas locale on its way to SpaceX’s McGregor testing facilities.

Signified by the outlines of unusual bumps under the Falcon booster’s protective shrink wrap, this probable Falcon Heavy center core’s Texas arrival indicates that SpaceX has most likely completed static fire testing of both side boosters, with the second booster now likely to depart McGregor and/or arrive at SpaceX’s Florida facilities in the coming weeks.

In February 2018, Falcon Heavy took flight for the first time ever, bringing to an end an almost mythical series of delays that pushed the rocket’s debut back more than five years. Aside from the unintentional demise of Falcon Heavy Flight 1’s center core, the inaugural launch was a spectacular and technologically valuable success, perfectly verifying the rocket’s ability to safely ignite, launch, separate, and recover two Falcon 9-class boosters simultaneously. SpaceX also took the opportunity – a payload with no practical value aside from inspiration – to perform a successful six-hour coast of the Falcon upper stage, demonstrating a capability critical for many potentially valuable launch contracts.

The next Falcon Heavy’s first side booster delivery was caught by several onlookers around December 21. (Instagram)

Now verified by planning schedules, SpaceX plans to attempt a truly impressive feat in the first half of 2019. Assuming all goes well during the center booster’s static fire and the subsequent integration and static fire of all three first stages, the company intends to launch the same Falcon Heavy hardware (all three boosters) twice in as little as two months, currently tentatively penciled in for February/March and April 2019.

Corroborated a few weeks ago by a NASA official involved in one of the payloads that will be present on that planned April launch, SpaceX plans to attempt recovery of both the side boosters and center core and rapidly refurbish them after their first launch in February or March, nominally placing the 6000 kg (~13,200 lb) Arabsat 6A satellite into a high-energy orbit. Perhaps as few as 4-8 weeks later, the rocket will be reintegrated, perform a second static fire at Pad 39A, and launch once again with a USAF rideshare known as Space Test Program (STP) 2, a program specifically designed to allow the Air Force to support low-risk test launches of unproven rockets.

Even more so than the fact that an ~8-week Falcon Heavy turnaround would simultaneously break SpaceX’s previous booster turnaround record in triplicate, the biggest reason to be skeptical of these plans is the fact that this schedule appears to require that the USAF fly a mission on not one but three flight-proven Falcon boosters. This stands at odds with the military branch’s unwillingness (by all appearances) to so much as allow a brand new Falcon 9 enough propellant margin (typically just a few percent) to land itself after the December 23rd launch of GPS III SV01, let alone allow their satellites to ride on a previously-flown rocket.

 

The major wrench in the machine here is the fact that GPS III SV01 most likely cost the USAF upwards of $700M to procure and will ultimately become a critical part of a widespread infrastructural upgrade, whereas STP-2 features two dozen or so small satellites worth dramatically less than the single GPS satellite SpaceX launched last month. STP-2 also operates under a program that is in large part meant to offer opportunities for new or wholly unproven launch vehicles (like Falcon Heavy) to conduct experimental launches, carrying the assumption that certifying those rockets for national security space (NSS) missions would be in the best interests of the Air Force and DoD.

As such, the back-to-back Falcon Heavy launch schedule is by no means impossible despite the fact that it offers up many reasons to doubt its plausibility. Either way, the fact that the next Falcon Heavy’s center core has already left SpaceX’s Hawthorne factory – following in the footsteps of two new side boosters – is a nearly unequivocal sign that the rocket’s second launch rapidly approaching.

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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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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.

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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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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.

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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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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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