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The first Block 5 version of Falcon Heavy prepares for its launch debut. The first Block 5 version of Falcon Heavy prepares for its launch debut.

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SpaceX’s first Falcon Heavy launch in three years eyes late-October liftoff

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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.

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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.

A new Falcon Heavy side booster. The USSF-44 upper stage, captured a week prior in much better detail below, is also slightly visible to the right of it. (SpaceX)
USSF-44’s Falcon upper stage was first pictured on September 23rd, when Crew-5’s Dragon spacecraft arrived at the same Pad 39A hangar. (SpaceX)
A similar greyed-out upper stage is visible on CRS-18’s Falcon 9 upper stage in July 2019. (SpaceX)

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.

During Falcon Heavy processing, the T/E can only fit inside the Pad 39A hangar after the rocket is fully assembled and suspended by cranes. (SpaceX)

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.

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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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Tesla Semi futuristic sci-fi acceleration sound will never get old

Videos that capture the Semi moving at speed are most notable due to their sheer cool factor.

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Credit: Tesla Owners Silicon Valley/X

The Tesla Semi is not yet in mass production, but the company has accumulated over 7.9 million miles across its test fleet. With Tesla using the Semi for its operations, it is no surprise that sightings of the Class 8 all-electric truck have been abounding. 

These sightings from Tesla enthusiasts vary, but those that capture the the Class 8 all-electric truck moving at speed are most notable, possibly due to their sheer cool factor.

Tesla Semi’s Roar

There is something that just stands out with the Semi, particularly on the road. While the Semi does not have the Cybertruck’s brutalist, angular design, it is still very striking because it’s such a massive machine that moves far too quietly for its size. This is, of course, one of the reasons why the vehicle also becomes extra noteworthy when it fires up its electric motors and accelerates.

Take this video from Tesla Owners Silicon Valley, for example, which shows the all-electric hauler accelerating while pulling what appears to be a full load. In these situations, the Tesla Semi actually becomes audible, but unlike traditional diesel-powered truck, the Class 8 all-electric truck “roars” with its own, unique futuristic, sci-fi sound. In such situations, one could feel the Semi’s raw power, which comes from its three independent motors on its rear axles.

Tesla Semi Ramp

Tesla has been promoting the Semi quite a bit as of late, and recent reports have suggested that the company is putting in a lot of effort to prepare the vehicle for its production in Nevada. Tesla’s Careers website has gone live with over 80 Semi-related job openings recently as well, and a recent report has suggested that Tesla has ramped the Semi’s factory workers in Nevada to over 1,000 employees.

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The company has even shared an update video of the Semi factory’s progress near Giga Nevada, as well as the design of the vehicle’s new logo. The Semi’s updated logo is quite interesting as it features elements from the Tesla Model 3’s first logo, which was unveiled way back in 2016.

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Robots like Tesla Optimus are a $5 trillion opportunity: analyst

This massive opportunity could be tapped by Tesla, thanks to its Optimus humanoid robot.

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tesla-optimus-pilot-production-line-fremont-factory
Credit: Tesla

Morgan Stanley analysts have estimated that the humanoid robot market could offer a $5 trillion opportunity by the middle of the century. This massive opportunity could be tapped by Tesla, thanks to its Optimus humanoid robot.

The analysts, however, noted that the humanoid robots will likely be mostly used in industrial and commercial deployments.

The Estimates

Estimates from Morgan Stanley analysts point to humanoid robots hitting $5 trillion in global revenue by 2050. This, the analysts noted, would be about double the total revenue of the 20 largest automakers in 2024. In 2050, Morgan Stanley analysts estimated that there might be about 1 billion humanoid robots deployed.

As noted in a report from Investing.com, the shift to humanoid robots would be gradual. By 2035, the analysts estimated that just about 13 million humanoid robots will be in use, most of which will be used in industrial and commercial settings. Even in 2050, when the analysts estimated that 1 billion humanoid robots will be in use, an estimated 90% might still be used in industrial and commercial settings.

The advent of humanoid robots will likely be felt in the labor sector, Morgan Stanley analysts noted. By 2030, the analysts noted that humanoid robots could replace about 40,000 jobs. Just ten years later, in 2040, the number of jobs that robots could take over could balloon to 8.4 million. By 2050, the analysts noted that 62.7 million humans may end up watching humanoid robots do their jobs.

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Tesla Potential

Morgan Stanley noted that companies like Tesla, which control the “brains, bodies, branding and ecosystems” of the humanoid robots, would be able to offer the highest value. This is good news for Tesla’s Optimus program, as it is a product that is designed to be produced at an extreme scale. During the Q1 2025 All Hands meeting, Elon Musk reiterated the idea that Optimus could very well become the biggest product of all time.

Most importantly, Musk also stated that Tesla is internally aiming to acquire enough resources to produce 10,000 to 12,000 Optimus robots this year. But even if Tesla just manages half of this number, or about 5,000 Optimus robots this year, it would already be impressive.

“Even 5,000 robots, that’s the size of a Roman legion, FYI, which is like a little scary thought. Like a whole legion of robots, I’ll be like ‘whoa.’ But I think we will literally build a legion, at least one legion of robots this year, and then probably 10 legions next year. I think it’s kind of a cool unit, you know? Units of legion. So probably 50,000-ish next year,” Musk stated.

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SpaceX set to launch Axiom’s mission for diabetes research on the ISS

Axiom’s Ax-4 will test CGMs & insulin stability in microgravity—potentially reshaping diabetes care for Earth & future astronauts.

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(Credit: SpaceX)

Axiom Space’s Ax-4 mission is set to launch on a SpaceX Falcon 9 rocket. Ax-4 will advance diabetes research in microgravity, marking a milestone for astronaut health.

Axiom Space’s fourth crewed mission is scheduled to launch with SpaceX on May 29 from NASA’s Kennedy Space Center in Florida. The Ax-4 mission will carry a diverse crew and a record-breaking scientific payload to the International Space Station (ISS).

The Ax-4 crew is led by Axiom’s Peggy Whitson and includes Shubhanshu Shukla from India, Sławosz Uznański from the European Space Agency, and Tibor Kapu from Hungary. The mission represents firsts for India, Hungary, and Poland, with Uznański being Poland’s first astronaut in over 40 years.

Ax-4 will conduct nearly 60 science investigations from 31 countries during its two-week ISS stay. A key focus is the “Suite Ride” initiative, a collaboration with Burjeel Holdings to study diabetes management in microgravity.

“The effort marks a significant milestone in the long-term goal of supporting future astronauts with insulin-dependent diabetes (IDDM), a condition historically deemed disqualifying for spaceflight,” Axiom noted. The mission will test Continuous Glucose Monitors (CGMs) and insulin stability to assess their performance in space.

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Axiom explained that testing the behavior of CGMs and insulin delivery technologies in microgravity and observing circadian rhythm disruption could help diabetes experts understand how CGMs and insulin pens can improve diabetes monitoring and care in remote or underserved areas on Earth. The research could benefit diabetes management in isolated regions like oil rigs or rural areas.

The mission’s findings on insulin exposure and CGM performance could pave the way for astronauts with diabetes to safely participate in spaceflight. As Axiom and SpaceX push boundaries, Ax-4’s diabetes research underscores the potential for space-based innovations to transform healthcare on Earth and beyond.

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