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SpaceX’s first Falcon Heavy launch in three years eyes late-October liftoff
For the second time in 2022, SpaceX’s Falcon Heavy rocket has a firm launch date for the first time in more than three years.
Cursed by a seemingly relentless flood of delays impacting almost every one of the rocket’s payloads, Falcon Heavy made it within three or four months of ending its launch drought as recently as June 2022. At the time, the rocket was more or less ready to begin assembly, but NASA announced late that month that the Jet Propulsion Laboratory (JPL) and supplier Maxar had failed to finish qualifying software needed to power its Psyche spacecraft. Designed to journey to and enter orbit around the asteroid 16 Psyche, the complex trajectory required to reach it constrained the mission to a launch window sometime between August and October.
When JPL and Maxar were unable to properly test the spacecraft’s software in time for that window, they were forced to stand down and wait until the next earliest window, which begins in July 2023. That left Falcon Heavy with three more possible payloads to launch in 2022, but all three were chronically delayed and there was little reason to believe that even one of them would be ready to launch before 2023. However, Falcon Heavy’s single most delayed payload appears to have made a breakthrough, giving the most powerful rocket currently in operation at least one more shot at a 2022 launch.
Continuing an excellent series of reports tracking Falcon Heavy’s never-ending US military payload delays, Spaceflight Now broke the news with an official statement from the US Space Force, which confirmed that an unspecified industry partner had finally resolved payload problems that have delayed the military’s USSF-44 mission by two years. More importantly, the USSF spokesperson revealed a specific target of October 28th.
The US military has repeatedly offered implausible launch targets for USSF-44 with little to no official explanation for the mission’s delays, making it reasonable to appraise any specific launch date much like a boy crying wolf. But this particular target, announced within the same month as its date, is a bit more believable on its own.
Thankfully, it’s not on its own. On October 7th, SpaceX sent out an email confirming that Falcon Heavy is scheduled to launch USSF-44 sometime in October and asking members of the media to register for press site access and remote camera setup opportunities. It’s possible that the rocket or USSF-44 satellites will run into issues and trigger additional delays, but a press accreditation email is about as close as one can get to a believable guarantee that a secretive US military payload is on track for a SpaceX launch scheduled more than a week or so in the future.
The mission’s next major step forward will be the assembly of Falcon Heavy inside SpaceX’s main hangar at its NASA Kennedy Space Center LC-39A pad. Photos SpaceX shared last month and earlier this month of preparations for Crew-5, Falcon 9’s eighth successful astronaut launch, show that at least two of the four main stages that make up Falcon Heavy are already inside that hangar. One of two new Falcon Heavy side boosters was clearly spotted on September 30th.
The rocket’s expendable upper stage was also clearly visible in a September 23rd photo. Ordinarily, Falcon upper stages are nearly indistinguishable from each other, but the upper stage stored behind the Crew-5 upper stage in the foreground features a unique grey band around the bottom of its airframe. In July 2019, SpaceX tested another Falcon 9 upper stage with the same grey band, which a spokesperson explained was meant to improve the rocket’s longevity in orbit.
Long orbital coasts of six or more hours are necessary for some of the most challenging launch trajectories. Direct-to-geostationary launches are the most common type of mission to require long coast capabilities and are often demanded by the US military. The grey band’s purpose is to increase the amount of heating absorbed from sunlight to warm the liquid kerosene (RP-1) fuel contained within that part of the rocket. When it gets too cold, kerosene – which freezes at a much higher temperature than Falcon’s liquid oxygen oxidizer – becomes viscous and slush-like before it freezes solid. If ingested, slushy fuel would likely prevent ignition or destroy the upper stage’s Merlin engine.
USSF-44 will be SpaceX’s first direct geostationary launch attempt, explaining why the grey band has reappeared more than three years after its first test. Coincidentally, Falcon Heavy’s third and latest launch occurred in June 2019, just one month before that upper stage test. 40 months later, the rocket might finally launch again, and it will do so by attempting what is likely SpaceX’s most difficult customer mission to date. To enable the high performance required for the mission, USSF-44 will also intentionally expend a Falcon Heavy booster for the first time. The rocket’s two new side boosters will boost back to Florida and land side by side at LZ-1 and LZ-2, but its new center core will be expended after a single flight.
SpaceX has already finished converting Pad 39A’s mobile transporter/erector, which was previously set up for single-core Falcon 9 rockets. The T/E will eventually roll inside the pad’s integration hangar, confirming that Falcon Heavy has been fully assembled and is about to be installed on the structure. The rocket will then be rolled out to the pad and brought vertical for static fire testing, a process that will likely begin at least a week before the current October 28th launch target.
If testing is successful, Falcon Heavy will return to the hangar, have its fairing and USSF-44 payload installed, and roll out to the pad one last time. Stay tuned for updates on that ongoing process.
News
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years.
The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Dry cathode 4680 cells
In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.
The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”
Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.
4680 packs for Model Y
Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla:
“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”
The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.
Elon Musk
Tesla Giga Texas to feature massive Optimus V4 production line
This suggests that while the first Optimus line will be set up in the Fremont Factory, the real ramp of Optimus’ production will happen in Giga Texas.
Tesla will build Optimus 4 in Giga Texas, and its production line will be massive. This was, at least, as per recent comments by CEO Elon Musk on social media platform X.
Optimus 4 production
In response to a post on X which expressed surprise that Optimus will be produced in California, Musk stated that “Optimus 4 will be built in Texas at much higher volume.” This suggests that while the first Optimus line will be set up in the Fremont Factory, and while the line itself will be capable of producing 1 million humanoid robots per year, the real ramp of Optimus’ production will happen in Giga Texas.
This was not the first time that Elon Musk shared his plans for Optimus’ production at Gigafactory Texas. During the 2025 Annual Shareholder Meeting, he stated that Giga Texas’ Optimus line will produce 10 million units of the humanoid robot per year. He did not, however, state at the time that Giga Texas would produce Optimus V4.
“So we’re going to launch on the fastest production ramp of any product of any large complex manufactured product ever, starting with building a one-million-unit production line in Fremont. And that’s Line one. And then a ten million unit per year production line here,” Musk stated.
How big Optimus could become
During Tesla’s Q4 and FY 2025 earnings call, Musk offered additional context on the potential of Optimus. While he stated that the ramp of Optimus’ production will be deliberate at first, the humanoid robot itself will have the potential to change the world.
“Optimus really will be a general-purpose robot that can learn by observing human behavior. You can demonstrate a task or verbally describe a task or show it a task. Even show it a video, it will be able to do that task. It’s going to be a very capable robot. I think long-term Optimus will have a very significant impact on the US GDP.
“It will actually move the needle on US GDP significantly. In conclusion, there are still many who doubt our ambitions for creating amazing abundance. We are confident it can be done, and we are making the right moves technologically to ensure that it does. Tesla, Inc. has never been a company to shy away from solving the hardest problems,” Musk stated.
Elon Musk
Rumored SpaceX-xAI merger gets apparent confirmation from Elon Musk
The comment follows reports that the rocket maker is weighing a transaction that could further consolidate Musk’s space and AI ventures.
Elon Musk appeared to confirm reports that SpaceX is exploring a potential merger with artificial intelligence startup xAI by responding positively to a post about the reported transaction on X.
Musk’s comment follows reports that the rocket maker is weighing a transaction that could further consolidate his space and AI ventures.
SpaceX xAI merger
As per a recent Reuters report, SpaceX has held discussions about merging with xAI, with the proposed structure potentially involving an exchange of xAI shares for SpaceX stock. The value, structure, and timing of any deal have not been finalized, and no agreement has been signed.
Musk appeared to acknowledge the report in a brief reply on X, responding “Yeah” to a post that described SpaceX as a future “Dyson Swarm company.” The comment references a Dyson Swarm, a sci-fi megastructure concept that consists of a massive network of satellites or structures that orbit a celestial body to harness its energy.
Reuters noted that two entities were formed in Nevada on January 21 to facilitate a potential transaction for the possible SpaceX-xAI merger. The discussions remain ongoing, and a transaction is not yet guaranteed, however.
AI and space infrastructure
A potential merger with xAI would align with Musk’s stated strategy of integrating artificial intelligence development with space-based systems. Musk has previously said that space-based infrastructure could support large-scale computing by leveraging continuous solar energy, an approach he has framed as economically scalable over time.
xAI already has operational ties to Musk’s other companies. The startup develops Grok, a large language model that holds a U.S. Department of Defense contract valued at up to $200 million. AI also plays a central role in SpaceX’s Starlink and Starshield satellite programs, which rely on automation and machine learning for network management and national security applications.
Musk has previously consolidated his businesses through share-based transactions, including Tesla’s acquisition of SolarCity in 2016 and xAI’s acquisition of X last year. Bloomberg has also claimed that Musk is considering a merger between SpaceX and Tesla in the future.
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
Tesla Giga Texas to feature massive Optimus V4 production line
