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SpaceX to livestream Falcon Heavy Block 5 launch debut at 6:15pm ET today

SpaceX CEO Elon Musk celebrates the success of Falcon Heavy's 2018 launch debut. (SpaceX/National Geographic)

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SpaceX is half a day away from the planned launch debut of Falcon Heavy Block 5, a milestone that will also be the rocket’s second launch ever and first mission with a commercial payload.

First and foremost, Falcon Heavy’s job is to safely place the Saudi Arabian communications satellite Arabsat 6A into a high-energy geostationary transfer orbit (GTO) more than 35,000 km (~22,000 mi) above Earth’s surface. Despite the satellite weighing no less than 6000 kg (13,200 lb), Falcon Heavy will still have enough latent performance to attempt the recovery of all three of its new Block 5 boosters. With any luck, this will hopefully return SpaceX’s East Coast landing zones (LZ-1 and LZ-2) to successful operations after an anomaly in December 2018 caused Falcon 9 B1051 to landing a mile or so offshore.

This time around, Falcon Heavy will be made entirely out of Block 5 hardware, including three new boosters (likely B1052, B1053, and B1055), a Block 5 upper stage with a Merlin Vacuum engine, and a recovery-optimized “Version 2” payload fairing. Altogether, Falcon Heavy likely weighs upwards of 80,000 kg (175,000 lb) empty and more than 1,420 metric tons (3,125,000 lb) when fully fueled. At liftoff, the Falcon Heavy Block 5 rocket’s 27 Merlin 1D engines are expected to produce no less than 5.1 million pounds (~2300 mT/23,000 kN) of thrust at full throttle, but that figure could rise as high as 5.6 million pounds (2550 mT/25,500 kN) of thrust depending on how one interprets rather vague official numbers from CEO Elon Musk.

Regardless, both Falcon Heavy side boosters will attempt to repeat the iconic side-by-side landings that are now a signature of the rocket’s 2018 launch debut, while the center core – traveling much faster at the point of stage separation – will travel nearly 1000 km (620 mi) downrange for a landing aboard drone ship Of Course I Still Love You (OCISLY). Ranging from multiple sonic booms that will be audible for miles up and down the Florida coast and the potential to a potentially spectacular Florida sunset as a backdrop, Falcon Heavy’s second launch will be an event worth watching.

The first Block 5 version of Falcon Heavy prepares for its launch debut. The rocket is comprised of three first stage boosters, likely B1052, B1053, and B1055. (SpaceX)

Falcon Heavy Flight 2 is made even more exciting by the fact that both of its Block 5 side boosters will be instrumental to a planned third launch of the SpaceX rocket as few as two months later. According to the US Air Force, an agreement was reached with SpaceX to use the opportunity – an intentionally low-risk mission known as Space Test Program 2 (STP-2) – to gain a much higher-fidelity understanding of how SpaceX launches, lands, refurbishes, and relaunches Falcon boosters. Aside from being the last major source of data for the ultimate certification of Falcon Heavy for high-value military launches, the USAF hopes that STP-2 will be a critical step towards opening the doors of launch contract competitions to flight-proven rockets like Falcon 9 and – eventually – Blue Origin’s New Glenn.

SpaceX’s launch webcast will go live approximately 20 minutes before liftoff, with the window stretching from 6:35 pm to 8:31 pm EDT (22:35-00:31 UTC). Weather is expected to be decent and is currently holding around 80% “go” for launch.

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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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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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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.

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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Investor's Corner

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.

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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