News
SpaceX’s Falcon Heavy flies a complex mission for the Air Force in launch video
SpaceX has gone to unique lengths for the third launch of its Falcon Heavy rocket and made an exhaustive webpage dedicated to the mission, reviewing its importance to SpaceX and the United States and discussing most of its 23 manifested spacecraft.
Known as the US Air Force’s Space Test Program 2 (STP-2) mission, Falcon Heavy Flight 3 will be a critical pathfinder for the US military’s systematic utilization of both Falcon Heavy and its flight-proven boosters.
The STP-2 mission will be among the most challenging launches in SpaceX history with four separate upper-stage engine burns, three separate deployment orbits, a final propulsive passivation maneuver and a total mission duration of over six hours. [It] will demonstrate the capabilities of the Falcon Heavy launch vehicle and provide critical data supporting certification for future National Security Space Launch (NSSL) missions. In addition, [the USAF] will use this mission as a pathfinder for the [military’s systematic utilization of flight-proven] launch vehicle boosters.
SpaceX, April 2019
SpaceX offers a very effective summary of the various challenges presented by Falcon Heavy’s STP-2 mission and third launch. It’s as challenging as it is for one very specific and largely artificial reason. All the way back in 2012, the USAF contracted the launch to give SpaceX a low-risk opportunity to demonstrate specific capabilities the military branch requires before they certify a given rocket to launch high-value payloads. Originally intended to fly STP-2 in mid-2015, Falcon Heavy suffered almost five years of delays during its development, caused by a combination of unexpected technical difficulties and two catastrophic Falcon 9 failures in 2015 and 2016.
After spending the whole of 2017 gradually catching up on delayed customer launches, SpaceX successfully conducted Falcon Heavy’s launch debut on February 6th, 2018. Four months later, the Air Force announced that it had completed the SpaceX rocket’s preliminary certification and awarded the company a $130M launch contract for AFSPC-52, a classified military satellite. According to documents describing the mission, the satellite weighs approximately 6350 kg (~14,000 lb) and needs to be placed into a geostationary transfer orbit (GTO) measuring 35,188km X 185km (21,850 mi X 115 mi).
Conveniently, Falcon Heavy’s commercial launch debut saw the massive rocket deliver the communications satellite Arabsat 6A – weighing ~6450 kg (~14,200 lb) – into an extremely high GTO, almost 90,000 km X 330 km (56,000 mi X 205 mi). In simpler terms, Falcon Heavy Flight 2 was an almost perfect demonstration that SpaceX is more than capable of successfully launching AFSPC-52, a milestone that could come as early as H2 2020.
The STP-2 mission should help to boost the US military’s confidence in Falcon Heavy even further. The mission is comprised of 23 separate satellites from a dozen or so different groups, ranging from a NOAA weather satellite constellation to a NASA-built atomic clock. The purpose of such a varied range of payloads is to have SpaceX’s Falcon upper stage (S2) place three separate sets into three distinctly different Earth orbits, a challenge that will require the rocket to ignite its Merlin Vacuum engine four times and survive in space for more than six hours.
SpaceX has been testing this critical long-coast technology since at least February 2018, when Falcon Heavy’s debut included a six-hour coast of the upper stage to send a Tesla Roadster on an Earth escape trajectory. SpaceX completed that test successfully and said Roadster is now orbiting the sun on a trajectory that regularly reaches beyond the orbit of Mars. SpaceX has continued to test the longevity of its universal Falcon upper stage, including a handful of on-orbit demonstrations after completing customer missions.
Aside from opening the door for new areas of competition in military launch procurement, successfully proving the long-coast capabilities of the Falcon upper stage will also mean that SpaceX can offer them commercially. Military launches often require long coasts in order to get spacecraft to their operating orbits as quickly as possible, typically involving an upper stage burning at the top of a transfer orbit to circularize said orbit. This capability can also be of significant value to non-government customers, however, as the faster a satellite can get to its operational orbit, the faster its owner can start using it to generate revenue. Traditionally, most commercial geostationary communications satellites are sent to transfer orbits, raising one end of the orbit (apogee) but leaving the low end (perigee) in low Earth orbit. Satellites then use their own propulsion systems to circularize their orbits before they can begin commercial operations.
It’s safe to assume that SpaceX is interested in commercially offering services like those above to make Falcon Heavy even more competitive with the likes of ULA’s Atlas/Delta/Vulcan rockets and Arianespace’s Ariane 5 and Ariane 6. The US military will almost certainly be the anchor customer, but a reliable upper stage with long-coast capabilities may one day allow Falcon Heavy to routinely launch commercial satellites directly into circular orbits or send flagship NASA spacecraft into deep space. But first, STP-2. According to Taiwan space agency NSPO, involved in the mission through their Formosat-7 constellation (also known as NOAA’s COSMIC-2), Falcon Heavy could launch STP-2 as early as June 22nd.
SpaceX’s dedicated STP-2 webpage can be viewed here.
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A common misconception of anti-EV proponents is that the batteries used in the vehicles are detrimental to the environment and that they cause more waste than they are worth. But a look at Tesla’s battery recycling efforts last year shows the company is doing more than ever to recover materials and give portions of the cells a second life.
Tesla reported a significant milestone in its sustainability efforts last year, with battery recycling volumes rising 20% compared to 2024. According to the company’s 2025 Impact Report, Tesla recycled over 14,000 metric tons of battery material through a combination of in-house processing at its Gigafactories and collaborations with third-party recycling partners.
Tesla: “In 2025, we recycled over 14,000 metric tons of battery material through a combination of in-house processing and through our network of recycling partners.”
That’s equivalent to 46,000 long-range battery packs, a +20% increase from 2024. pic.twitter.com/TC3Nz7Kaqf
— Sawyer Merritt (@SawyerMerritt) July 7, 2026
This amount of recovered material is equivalent to the resources needed to produce approximately 46,000 long-range battery packs. The increase reflects growing operational scale as Tesla’s global vehicle fleet expands and more batteries reach end-of-life or manufacturing scrap becomes available for processing.
Tesla and Battery Recycling
Battery recycling forms a core part of Tesla’s circular economy strategy. The company designs its batteries for longevity, often exceeding 200,000 miles of driving, and prioritizes repairs, remanufacturing, and second-life applications before full recycling.
Once packs are decommissioned, Tesla ensures 100% are recycled with no materials sent to landfills. This approach recovers critical metals including lithium, nickel, cobalt, and copper, which can be refined and reused in new battery production.
Tesla has advanced hydrometallurgical recycling processes capable of achieving recovery rates up to 98% for key battery metals. These methods are more efficient and environmentally friendly than traditional pyrometallurgical techniques, reducing energy use and enabling higher-purity materials suitable for direct reintegration into battery manufacturing.
Tesla co-founder JB Straubel confirms Redwood’s battery recycling operations are already profitable
In-house capabilities are supplemented by a network of specialized partners, creating a robust system that handles both production scrap and end-of-life packs.
The environmental and economic benefits are substantial. Recycling reduces reliance on virgin mining, lowers the carbon footprint associated with raw material extraction and processing, and helps stabilize supply chains for critical minerals amid rising global EV demand. As millions of Tesla vehicles age, the volume of recyclable material is expected to grow significantly in the coming years.
This 20% year-over-year growth demonstrates the effectiveness of Tesla’s investments in recycling infrastructure and technology. It positions the company as a leader in addressing one of the automotive industry’s major sustainability challenges. Continued innovation in battery design for easier disassembly and higher recyclability will further enhance these efforts.
Overall, Tesla’s progress in 2025 highlights how scaling recycling operations supports both environmental goals and long-term business resilience in the transition to electric mobility. As the EV market matures, such closed-loop systems will become increasingly vital for sustainable growth.
Tesla has spent years trying to engineer its way out of the automotive paint shop, one of the most expensive, space-consuming, and environmentally costly steps in vehicle manufacturing. With the Cybercab, Tesla confirmed on X this week that a new reaction injection molding process will embed color directly into the panel itself during production.
“Our new reaction injection molding (RIM) process shrinks Cybercab paint cycles from hours to minutes. This cuts those parts’ manufacturing and supply chain emissions by 35% and eliminating 100% of paint volatile organic compounds (VOCs) emitted in traditional paint methods.” noted Tesla.
While the RIM process isn’t necessarily new and has existed since the 1960s, what makes Tesla’s application notable is how it is being used specifically for exterior body panels that traditionally required a separate paint process after forming.
Tesla’s RIM approach integrates the color directly into the panel material during the molding process itself. The pigment is part of the polymer mix injected into the mold, meaning the panel comes out of the mold already colored, with no separate paint application required. The clear coat or protective layer can be applied at the mold stage or through a much faster post-process than traditional multi-stage painting. Tesla claims this compresses what was a multi-hour paint cycle into minutes per panel.
Tesla’s obsession with killing the paint shop is one of the most consistent threads running through the company’s manufacturing philosophy going back years. As far back as 2018, Musk was trimming paint color options to simplify production, tweeting at the time: “Moving 2 of 7 Tesla colors off menu on Wednesday to simplify manufacturing.” Two years later, in a 2020 Automotive News interview, Musk laid out his broader vision, saying he believed Tesla factories could one day be 1,000 times more efficient than conventional plants, and pointing to the paint shop as one of the biggest sources of waste, cost, and complexity. The Cybertruck was the most extreme expression of that thinking. Tesla chose an unpainted stainless steel exterior partly because it would eliminate the need for a $200 million paint facility at Gigafactory Texas. The stainless approach proved harder and more expensive than anticipated, but the underlying ambition never changed. The Cybercab is what happens when that same ambition meets a manufacturing process that delivers on it.
Lifestyle
Tesla app update makes Robotaxi ownership make a lot more sense
Tesla’s app now shows a live indicator when your car is actively driving itself.
A recent Tesla app update, released last week (4.58.5), gives visibility on whether a vehicle is navigating in its semi-autonomous mode or being drive by a human driver. The updated app now displays a live “Self-Driving” indicator in bright blue text directly beneath the vehicle’s speed readout whenever Full Self-Driving is actively engaged, along with the signature glowing blue navigation path that FSD users see on the main touchscreen. It is a small visual update with meaningful implications for how Tesla owners monitor their vehicles remotely.
The feature was first spotted in the wild by X user Jordan Camina, who shared video of a Hardware 3 Model S displaying the new animation through the app while driving. That detail is significant because it confirms the update is not limited to newer HW4 vehicles. It works across hardware generations, and Tesla confirmed it will eventually support all vehicles regardless of chip platform once both the app and vehicle software are updated. The vehicle side requires software version 2026.20.6.1, which has reached nearly 40% of the fleet so far, as monitored by NotaTeslaApp.
The feature makes the most practical sense when viewed through the lens of Tesla’s expanding robotaxi operation. In a robotaxi context, the owner of a vehicle generating ride revenue has a direct financial and safety interest in knowing whether their car is operating under autonomous control at any given moment. The app’s new FSD indicator gives fleet owners exactly that visibility, the same way a logistics company monitors whether a delivery driver is following the planned route. It also carries implications for Tesla’s insurance model. Tesla’s own insurance product prices premiums in part based on FSD engagement rates, and real-time visibility into when FSD is active creates a feedback loop that could eventually tie directly into policy pricing. For individual owners who have opted their personal vehicles into the robotaxi network, the update effectively turns the Tesla app into a fleet management dashboard, one that tells you whether your car is earning money, whether it is driving itself to do it, and whether everything is operating the way it should from wherever you happen to be.
Tesla expands Robotaxi to Florida, marking its third state for autonomy
As Teslarati has reported, Tesla launched unsupervised robotaxi rides in Miami this summer, a milestone that makes a remote FSD status indicator significantly more practical than a cosmetic feature. When a vehicle is operating as a robotaxi without a driver present, the owner or fleet operator needs a reliable way to confirm autonomy is engaged. The app now provides exactly that.
As noted by NotATeslaApp, The update also arrived alongside a hint buried in the same app version that Tesla plans to use the cabin camera to verify driver identity before FSD can be activated. Pairing identity verification with a live autonomy status indicator points toward the infrastructure Tesla is building for a fleet of driverless vehicles that owners can monitor the way you would track a package delivery.
Tesla battery recycling efforts increased 20 percent last year
Tesla FSD is about to know your specific house and neighborhood better than any map
