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SpaceX Falcon Heavy rocket to launch record-breaking communications satellite

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A report on the latest in a long line of SpaceX launches significantly delayed by customer payload readiness has been updated to confirm that the satellite in question will launch on Falcon Heavy, not Falcon 9.

Hughes revealed that it had selected SpaceX to launch its Maxar-built Jupiter-3 geostationary communications satellite during an industry conference on March 21st, 2022. At the time, Hughes stated that the satellite was on track to launch in the fourth quarter of 2022, a refinement but also a delay from earlier plans to launch sometime in H2 2022. Just six weeks later, manufacturer Maxar reported that the completion of Jupiter 3 – like many other Maxar spacecraft – had been delayed, pushing its launch to no earlier than (NET) “early 2023.”

At the same time, Maxar revealed that Jupiter 3 – also known as Echostar 24 – was expected to weigh around 9.2 metric tons (~20,300 lb) at liftoff when that launch finally happens. That figure immediately raised some questions about which SpaceX rocket Hughes or Maxar had chosen to launch the immense satellite.

Earlier on, regulatory documents revealed that Jupiter 3 would have a dry weight of 5817 kilograms (~12,825 lb). In July 2018, SpaceX broke the record for heaviest commercial geostationary satellite launch when a Falcon 9 rocket successfully delivered Telesat’s 7076-kilogram (15,600 lb) Telstar 19V to geostationary transfer orbit (GTO). To account for the satellite’s weight and still allow for Falcon 9 booster recovery, SpaceX launched Telstar 19V to a transfer orbit with its apogee (high point) well below geostationary orbit, meaning that the satellite had to do more of the work of orbit-raising. In other words, it wasn’t inconceivable that Jupiter 3 would also be launched to a low (subsynchronous) GTO on a recoverable Falcon 9.

However, in hindsight, Jupiter 3’s 5.8-ton dry mass should have already made it clear that that was unlikely. Telstar 19V, for example, had a reported dry mass of just over 3 tons (~6700 lb), meaning that more than half its wet mass was fuel for orbit-raising and maneuvers. In more normal cases, large geostationary satellites tend to launch with an extra 50-80% of their dry mass in fuel, not ~130%. Even at the low end of large geostationary satellites, Jupiter 3 was likely to have a launch mass of well over 8 tons.

At 9.2 tons, Jupiter 3 will leapfrog the world record for the largest commercial geostationary satellite ever launched by 30%. Barring the possibility of secret military spacecraft, it will likely be the heaviest spacecraft of any kind to reach geostationary orbit 35,785 km (22,236 miles) above Earth’s surface. More importantly, Jupiter 3 may also have the heaviest dry mass of any spacecraft to reach GEO, meaning that the actual hardware it will use to fill its role as a communications hub will also be exceptionally large and powerful. Jupiter 3 will deliver a maximum bandwidth of 500 gigabits per second.

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With its exceptional heft, a recoverable Falcon 9 launch may have only been able to loft Jupiter 3 around half the way to GTO from low Earth orbit (LEO). It was little surprise, then, to learn that Hughes and Maxar had actually selected SpaceX’s far more capable Falcon Heavy rocket to launch the satellite. Even with full recovery of all three Falcon Heavy first-stage boosters, there’s a good chance that the rocket would be able to launch Jupiter 3 most of or all the way to a nominal geostationary transfer orbit. If the center core is expended and the side boosters land at sea, Falcon Heavy would likely be able to launch Jupiter 3 to a highly supersynchronous GTO, meaning that the spacecraft’s apogee would end up well above GEO. For example, on Falcon Heavy’s Block 5 launch debut, the rocket sent the ~6.5-ton (~14,250 lb) Arabsat 6A communications satellite to a GTO with an apogee of almost 90,000 kilometers (~56,000 mi), shaving about 20% off of the satellite’s orbit-raising workload.

Falcon Heavy’s Jupiter 3 mission won’t beat the record for total payload to GTO in a single launch, held by Arianespace’s Ariane 5 rocket after a 2021 mission to GTO launched two communications satellites weighing 10.27t, but it will be just one ton shy.

Jupiter 3 is the 10th mission firmly scheduled to launch on SpaceX’s Falcon Heavy rocket between now and 2025.

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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Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says

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Credit: United Airlines

United Airlines CEO Scott Kirby said that SpaceX’s Starlink satellite internet is its leading competitive advantage in the U.S. airline industry. However, in recent comments, while he described the service as “the biggest competitive advantage” the carrier currently holds, he also acknowledged that the edge is temporary.

“…everybody eventually is going to have high-speed low earth orbit internet connectivity. It’s going to be a must-have. We are going to have a few years of being the only airline that has it at scale, and that’s our mission,” Kirby said. Until everyone has it, United aims to capitalize on its head start by converting trial users into long-term loyal customers.

United has moved faster than its rivals on Starlink installations. As of mid-to-late October 2026, the system was on roughly 43 percent of its fleet, with plans to reach 61 percent by year-end, 87 percent by June 2027, and full fleet coverage by the end of next year.

The airline already operates more Starlink-equipped flights than the rest of the U.S. industry combined. Los Angeles International Airport is scheduled to become United’s first 100 percent Starlink hub in the first half of 2027, and the carrier’s app will display the likelihood that any given flight has the service.

Kirby has pointed to early evidence that the offering influences booking decisions. Some passengers loyal to other airlines are already switching flights for Starlink connectivity, something the airline, along with American Airlines, has tried to leverage against competing airlines. Both companies used status-match programs, and some of those customers are pursuing company-specific credit cards, which signals an intent to stay.

Once onboard, these customers encounter the airline’s broader investments in aircraft, larger seat-back screens, oversized bins, connection tools, and a mobile app that Kirby says outperforms competitors. Wi-Fi satisfaction scores on Starlink-equipped planes have been reported to be nearly double those on aircraft with other systems.

Competitors are moving slowly to do the same. Southwest Airlines began installations in 2025 and expects to complete them soon. Delta is pursuing Amazon’s Leo system, while American expects to start Starlink work in early 2027 and has not yet detailed regional-fleet plans. This timeline gap gives United a multi-year window in which it remains the only major U.S. carrier offering Starlink at scale.

Kirby has framed the strategy as pressing that advantage while simultaneously widening gaps in other technology areas so that customers who try United for the Wi-Fi remain for the overall experience.

The approach reflects a calculated bet that superior in-flight connectivity can accelerate share gains and support longer-term financial targets, including a 10 percent pre-tax margin goal.

High-speed internet is particularly valued by premium and business travelers who can work or stream reliably. As low-Earth-orbit service becomes ubiquitous, the temporary nature of the pure connectivity edge means United’s retention will depend on whether its other product and operational improvements keep pace.

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Tesla Cybercab’s unorthodox paint process explained

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Credit: Tesla

Tesla Cybercab skips the traditional paint shop entirely, marking an unorthodox process for coloring the fully autonomous vehicle. However, the decision was a smart one, as it slashed factory costs, floor space utilization, and complexity, since Tesla relied on specialized alloys and in-mold coloring.

Munro Live was given the opportunity to do a factory walkthrough with Tesla Vice President of Vehicle Engineering Lars Moravy, who explained and detailed how Cybercab production at Giga Texas eliminates one of the automotive manufacturing industry’s most expensive and space-hungry elements.

A conventional paint line can cost hundreds of millions of dollars and require a million man-hours to build. Moravy framed the choice around Tesla’s core rule: “Question the requirements: why do you need paint?”

The structural answer lies in material selection. The aluminum alloys used in Cybercab’s front and rear castings do not oxidize and lose strength over time, the way many common automotive aluminum alloys do. Only the side modules, built around hot-stamped boron-steel door rings, receive an anti-corrosion e-coat, or dip coat. Front and rear modules skip coating altogether.

Model Y and Model 3 bodies, by contrast, are fully coated and painted.

Exterior colors come from the plastics shop, which Tesla engineers described as “our paint shop” for the Cybercab. Body panels are produced via reaction injection molding, referred to as RIM. Color is then mixed into a polyurethane resin at the mix head immediately before injection, so the panel emerges already colored with a Class-A surface.

Robots trim overflow to control sink marks and flow lines. The process avoids conventional spray-paint defects like orange peel and paint bleed. Scratches can still be repaired with compatible coatings that behave “basically like paint.” Because color is integral rather than a surface layer, shallow scratches do not expose a contrasting undercoat.

The secret behind Tesla’s Cybercab Gold goes well beyond just the color

Tesla has also explored related approaches, including in-mold lamination and painted films on stamped panels.

The manufacturing payoff is substantial because removing the paint shop, combined with the “unboxed” modular process that builds and tests front, rear, side, and center modules in parallel before a short final assembly, cuts factory floor space per vehicle by about 50 percent.

Final assembly itself uses only about 25 automated stations, far fewer than the typical Model Y line, and the overall line runs at about 78 percent automation, Moravy said. The approach also eliminates volatile organic compound emissions associated with traditional spray painting for these panels and shortens the coloring cycle from hours to minutes.

Cybercab’s paint strategy is clearly less about aesthetics than about systematically deleting capital-intensive, energy-heavy, and space-consuming steps once material science and process design make them unnecessary. It is a concrete example of Tesla applying first-principles questioning to one of the auto industry’s most entrenched factory requirements.

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Tesla has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

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Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

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The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

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