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SpaceX’s Falcon Heavy rocket could launch a NASA space station to the Moon

SpaceX's Falcon Heavy rocket could potentially launch a new NASA space station all the way to the Moon. (SpaceX)

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According to NASA, a SpaceX Falcon Heavy rocket (or another commercial heavy-lift launch vehicle) could potentially launch the bulk of a new Moon-orbiting space station in a single go, saving money and reducing risk.

Known as the Gateway, NASA is working to build a tiny space station in an exotic and odd orbit around the Moon. Lacking any clear and pressing purpose, NASA and the Gateway’s proponents have argued that it could serve as a testbed for interplanetary missions, allowing the space agency to figure out how to keep astronauts alive and healthy in deep space. Later, it was proposed as a sort of unwieldy orbital tug and home base for crewed Moon landers, although the Gateway appears to have recently been removed from any plans for mid-2020s Moon landings.

Most likely, the station is being built in order to give NASA’s wildly over-budget, behind-schedule Orion spacecraft and SLS rocket some kind of destination worthy of their gobsmacking $2-3 billion launch cost and $35-40 billion development cost. Regardless, a space station orbiting the Moon – while lacking a clear and present scientific or exploratory reason for its existence – is undeniably cool and exciting and will indeed need to be launched into cislunar space. Previously planned to launch as separate modules that would then rendezvous and dock in at the Moon, NASA has recently decided to switch gears.

According to NASA, the near-term arrival of launch vehicles with extra-large commercial fairings has motivated a change in its space station launch strategy. (SpaceX)

As of May 2020, NASA has awarded three critical hardware contracts for Gateway. In 2019, the space agency awarded contracts to Maxar and Northrop Grumman to build the Power and Propulsion Element (PPE) and Habitation and Logistics Outpost (HALO), respectively. As the name suggests, the PPE will feature an exceptionally large ~50 kW solar array and the most powerful electric thrusters ever flown in space, thus supplying Gateway with electricity and propulsion. HALO is a miniscule habitat module also responsible for life support and providing all other basic necessities for astronauts to live in space, all of which will leave a tiny amount of actual habitable volume for those astronauts to live in.

Most recently, NASA also awarded SpaceX a contract to develop a new Dragon XL spacecraft that will launch on Falcon Heavy and autonomously resupply the lunar space station at least twice, should Gateway actually make it to launch.

NASA has selected SpaceX to deliver cargo to its upcoming Lunar Gateway. Credit: SpaceX
The Maxar PPE (far left) and (two) Northrop Grumman HALO modules are pictured here, as well as an Orion spacecraft (far right). (Northrop Grumman)

The notional plan is to eventually expand the habitable volume of the station from living in a large SUV to something more like a small studio apartment, a bit less than a third as large as the International Space Station (ISS) in a best-case scenario. The ISS is designed to support at least six astronauts simultaneously and has done so for almost two decades, albeit only with the help of resupply missions launched from Earth every 2-3 months. Indeed, the plan is to send up to four astronauts to the Gateway for no more than 90 days a year.

Two birds, one stone; two eggs, one basket

Originally, NASA wanted to launch the PPE and HALO modules – together representing the absolute bare minimum needed to build a functional Gateway – on separate commercial rockets in 2022 and 2023, respectively. Now, according to NASA associate administrator Doug Loverro, the space agency has made the decision to launch both modules simultaneously on the same commercial rocket.

In the next year or two, two new commercial rockets with spacious payload fairings (ULA’s Vulcan and Blue Origin’s New Glenn) could debut. A third, SpaceX’s Falcon 9 and Heavy rockets, will likely launch for the first time with a new extended payload fairing within the next 12-18 months. (Teslarati – ULA/NGIS/Blue Origin/SpaceX)

This decision was made in large part because it makes sense from a technical simplicity and overall efficiency standpoint but also because several commercial launch vehicles – either currently operational or soon to be – are set to debut extremely large payload fairings. As a combined payload, the Gateway PPE and HALO modules would be too big for just about any existing launch vehicle, while the tiny handful it might fit in lack the performance needed to send such a heavy payload to the Moon.

Falcon Heavy apparently has the performance needed, as NASA used the rocket and a new stretched fairing developed by SpaceX for military customers as a baseline to determine whether PPE and HALO could launch together. Given that NASA could have technically used any of the vehicles expected to have large payload fairings for that analysis, the explicit use and mention of Falcon Heavy rather strongly suggests that the SpaceX rocket is a front runner for the new combined launch contract. This isn’t exactly surprising, given that the massive rocket has already completed three successful launches and will attempt at least another four missions between now and 2023.

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Even with its stretched fairing, Falcon Heavy’s fairing volume will still be dwarfed by Blue Origin’s New Glenn rocket. (Blue Origin)

Of the other launch vehicles expected to feature large fairings capable of supporting the combined PPE/HALO payload, ULA’s Vulcan Centaur rocket is scheduled to launch for the first time in July 2021, while Blue Origin’s New Glenn is unlikely to launch before late 2021. Northrop Grumman is also developing the Omega rocket with a large fairing, although it’s unlikely to have the performance needed for the unique Gateway payload. As such, by 2023, Falcon Heavy will almost certainly have a record of launches well out of reach of other prospective PPE/HALO launch competitors. For obvious reasons, putting both modules of a space station on a single launch raises the stakes, making it more critical than ever than risk be reduced where it can be – especially important for launch operations.

Notionally including Gateway’s PPE and HALO, Falcon Heavy now has as many as nine launches on contract (or nearly so) over the next five or so years. It’s extraordinarily unlikely that any of Falcon Heavy’s prospective competitors will be able to get close to the SpaceX rocket’s flight history by 2023, effectively making Falcon Heavy the de facto choice for NASA from an apolitical, technical perspective.

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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Elon Musk

Elon Musk shuts down talk of TSMC taking over Terafab

Musk says Tesla and SpaceX will build and run Terafab, with TSMC limited to renting.

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SpaceX Terafab rendering

Elon Musk has drawn a firm line around who will be in charge of Terafab, the giant chip factory Tesla and SpaceX are planning in Texas.

Musk replied to a post on X arguing that Taiwan Semiconductor Manufacturing Company (TSMC) would most likely end up owning and operating the plant. “No, we will build and run the fab. Let there be ZERO doubt about that,” Musk wrote. “Maybe TSMC subleases part of the Terafab if they want, but nothing more than that.”

In plain terms, a sublease means TSMC could rent a section of the complex to make chips, similar to a tenant renting one floor of an office tower. The building, the equipment decisions and the daily operation would stay with Tesla and SpaceX.

The comment shuts down speculation that started last week. On October 2, tech journalist Tim Culpan reported that TSMC was exploring ways to help run Terafab’s factories. Musk responded the next day that it was “just discussions, but something may come of it,” as Teslarati reported at the time. That left room for a scenario where the world’s largest contract chipmaker took the wheel. Musk’s latest post closes that door.

Elon Musk teases TSMC as potential Terafab partner

Some background helps explain why this matters. Tesla designs its own AI chips today but pays outside companies like TSMC and Samsung to manufacture them. Musk unveiled Terafab in March as a joint project between Tesla, SpaceX and xAI, arguing that existing suppliers cannot expand fast enough to meet his companies’ future demand. The goal is to produce enough chips each year to supply one terawatt of computing power, roughly 50 times what the entire global AI chip industry produces now.

Those chips are meant for Tesla’s Optimus humanoid robots, the Cybercab and Full Self-Driving computers, along with chips for SpaceX’s planned data centers in orbit. Owning the factory means Musk’s companies would not have to compete with every other chip customer for time on someone else’s production lines.

Intel is still part of the picture. The company signed on in April to help design, build and package chips for the project, and CEO Lip-Bu Tan told Bloomberg this week that Intel will keep working on Terafab despite the TSMC chatter.

The project moved from concept to construction planning over the summer. In August, SpaceX confirmed the Grimes County site about an hour from Houston, sent the county a $10 million payment under its tax abatement deal and said civil work would begin shortly. The first phase carries a $16.8 billion price tag, and total spending across all phases could reach as much as $119 billion.

TSMC chairman C.C. Wei has said a new fab typically takes two to three years to build and another one to two years to reach full output. Tesla and SpaceX have never run one, which is why TSMC’s expertise drew so much attention. Musk’s answer suggests he would rather learn that process in house than hand control of a project this central to Tesla’s robotics and autonomy plans to an outside company.

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Elon Musk

Trump to hand Elon Musk a top honor that traces back to JFK

Trump will award Elon Musk the National Medal of Science at Thursday’s White House summit.

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elon musk and donald trump in front of a tesla cybertruck at the white house

Elon Musk is set to receive the highest honor the U.S. government gives to scientists and engineers.

President Donald Trump will present Musk with the National Medal of Science on Thursday at the White House’s Science: A New Golden Age Summit, Fox News Digital first reported on Wednesday. Google cofounder Sergey Brin, Nvidia CEO Jensen Huang and AMD CEO Lisa Su will receive the same medal, while Dell Technologies CEO Michael Dell and Microsoft CEO Satya Nadella will receive the National Medal of Technology and Innovation. A White House official later confirmed the list to Reuters.

“The Trump administration is grateful for the contributions of these incredible leaders in science and technology. These recipients are helping ensure America keeps leading the world in innovation,” White House spokesperson Liz Huston told Fox News.

It will be the first time Trump has presented either medal in his two terms. Congress created the National Medal of Science in 1959, and the National Science Foundation, which administers it, says 529 scientists and engineers have received it since. A presidential committee reviews nominees, but the president makes the final call.

Thursday’s group of medalists run or founded companies, and three of them sit at the center of the Super Intelligence hardware race that Musk competes in. Huang’s Nvidia supplies the GB300 chips filling SpaceX’s Colossus 2 cluster, while Su’s AMD is Nvidia’s biggest rival in data center GPUs.

Worth noting that Trump’s uncle, MIT physicist John G. Trump, received the National Medal of Science from President Ronald Reagan for his work on ionizing radiation and its uses in medicine and industry.

The Pentagon taps Elon Musk to design the battlefield of the future

For Musk, the medal is the latest sign of how far his relationship with Trump has come since their 2025 split over the “Big Beautiful Bill” and his exit from DOGE. Last week, he sat at Trump’s left during a White House lunch where AI executives signed a voluntary safety accord, and Defense Secretary Pete Hegseth named him to help lead the Pentagon’s Project Meridian study on the future of warfare. Musk has also adopted the administration’s new vocabulary, saying on Sunday that SpaceXAI will be renamed SpaceXSI after Trump ordered federal agencies to replace “artificial intelligence” with “super intelligence.”

Musk has collected science honors before, including the Stephen Hawking Medal for Science Communication in 2019.

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Tesla FSD changed its mind mid-intersection, and it may have saved a life

Tesla shares dashcam footage of FSD Supervised stopping mid intersection to avoid a T-bone crash.

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Credit: @BLKMDL3/X

Tesla is putting another Full Self-Driving save in front of its 24.8 million followers on X.

On Tuesday morning, Tesla’s main account shared a dashcam clip with the caption “FSD Supervised preventing T-bone crash.” The footage came from an owner posting as TheNewGrid, who described what happened at a stop sign: “I looked at the car coming to the stop sign figured they would stop, my car went, then came to a stop mid intersection as they flew by. Had I been manually driving this would have resulted in a crash.”

The sequence is the notable part. FSD had already started crossing when the other driver ran the stop sign. Instead of pressing on, the car braked hard in the middle of the intersection and let the crossing vehicle pass in front of it. By the owner’s own account, they had made the same assumption the software initially made, that the other car would stop, and would not have corrected in time.

The clip is the latest in a run of safety posts Tesla has amplified over the past several days. On Saturday, the company shared a video from Selling Sunset star Jason Oppenheim, who sold his Bentley for a Model Y and said he was buying Teslas with FSD for 10 of his employees. Ashok Elluswamy, who leads Tesla AI, followed up by writing that Tesla self-driving “reacts to other people cutting into your path with super-human response times.” On Monday, a Cybertruck owner posted footage of FSD moving across three lanes from a red light to clear a path for an ambulance approaching from behind.

This recent clip also lands a few weeks after Tesla began shipping Automatic Collision Evasion with FSD v14.3.9, a feature that can activate FSD on the driver’s behalf when a frontal collision is imminent or the driver appears distracted. Elluswamy said in September that “even earlier prediction of hazards, even faster reaction time and overall significantly better safety and collision avoidance” are coming with v15, the release Tesla has tied to round the clock Robotaxi operation.

The safety messaging matters beyond social media. Tesla has said FSD Supervised was 4.1 times less likely to crash than manual driving across 100 million kilometers on European roads, and it has been putting those figures in front of regulators. Eight EU countries have now approved FSD Supervised, with Croatia the most recent, but the EU’s bloc-wide vote originally set for October 6 has been pushed to December at the earliest.

FSD Supervised is still a Level 2 system, and the driver remains responsible at all times. Even heavy users find reasons to step in. Teslarati’s Joey Klender, who uses FSD for about 76 percent of his driving, laid out five recurring issues on Tuesday that still prompt him to intervene. Clips like this one show the other column of that ledger: moments where the software caught a mistake a human was about to make.

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