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SpaceX’s third Falcon Heavy launch on track as custom booster aces static fire

Falcon Heavy center core B1057 was spotted in transport on April 16th and performed a static fire test ten days later. (codercotton & SpaceX)

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SpaceX has successfully completed a static fire of its newest Falcon Heavy center core, a sign that the most challenging hardware is firmly on track for a late-June launch target.

Currently penciled in for June 22nd, Falcon Heavy’s third launch is of great interest to both SpaceX and its customer, the US Air Force. Most of the two-dozen payloads manifested on the mission are admittedly unaffiliated with the US military. However, the rideshare – known as Space Test Program 2 (STP-2) – was acquired by the USAF for the branch to closely evaluate and certify SpaceX’s Falcon Heavy rocket for critical military launches. The potential upsides of a successful demonstration and evaluation are numerous for both entities and would likely trigger additional positive offshoots.

The Center Core experience

Beyond the general contractual aspects of STP-2, the mission is significant because it will use the third Falcon Heavy center core and second Block 5 variant to be built and launched by SpaceX. Of the technical issues that complicated and delayed SpaceX’s Falcon Heavy development, most can probably be traced back to the rocket’s center core, practically a clean-slate redesign relative to a ‘normal’ Falcon 9 booster.

Most of that work centered around the extreme mechanical loads the center core would have to survive when pulling or being pulled by Falcon Heavy’s two side boosters. Not only would the center core have to survive at least two times as much stress as a Falcon 9 booster, but that stress would be exerted in ways that Falcon 9 boosters simply weren’t meant to experience, let alone survive. After years of work, SpaceX arrived at a design that dumped almost all of that added complexity squarely on the center core and the center core alone. The side boosters would need to use nosecones instead of interstages and have custom attachment points installed on their octawebs and noses, but they would otherwise be unmodified Falcon 9 boosters.

USAF photographer James Rainier's remote camera captured this spectacular view of Falcon Heavy Block 5 side boosters B1052 and B1053 returning to SpaceX Landing Zones 1 and 2. (USAF - James Rainier)
Falcon Heavy side boosters B1052 and B1053 land at Landing Zones 1 and 2 (LZ-1/LZ-2) after their launch debut and Falcon Heavy’s first commercial mission. (USAF – James Rainier)
Falcon Heavy center core B1055 lands aboard drone ship OCISLY around 10 minutes after launch. (SpaceX)

On top of that, SpaceX’s Falcon upper stage and payload fairing would require no major modifications to support Falcon Heavy missions. On the opposite hand, the center core would require extensive rework to safely survive the trials of launch, let alone do so in a fashion compatible with booster recovery and reuse. Per the landing photos above, it’s difficult to tell a Falcon Heavy center core apart from a normal Falcon 9 booster, but the small visible changes are just the tips of several icebergs. Aside from a slight indication that the center core’s aluminum alloy tank walls are significantly thicker (they are), center cores feature a variety of unique mechanisms on their octawebs and interstages. All are involved in the tasks of locking all three boosters together, transferring side booster thrust to the center core, and mechanically separating the side boosters from the center core a few minutes after launch.

Underneath those mechanistic protuberances are the structural optimizations needed for a center core to survive the ordeal of launch. In short, to solve for those new loads, SpaceX wound up building a new rocket. Designing and building a new rocket – especially one as complex as Falcon Heavy’s center core – is immensely challenging, expensive, and time-consuming, particularly for the first few built. Like most complex products, building the first two Falcon Heavy center cores was probably no different. To make things worse, boosters 1 and 2 were based on totally different versions of Falcon 9 (Block 3 vs. Block 5), requiring even more work to further redesign and requalify the modified rocket.

Falcon Heavy center core B1057 completed its McGregor, TX static fire on April 26th, 10 days after the same booster was spotted eastbound in Arizona. (SpaceX)

This is where the center core assigned to Falcon Heavy Flight 3 and pictured above comes into play. Built just a few months apart from B1055, the first finished Falcon Heavy Block 5 center core, the newest center core – likely B1057 – is also the first to be built with the same design and manufacturing processes used on its predecessor. In other words, SpaceX can at long last begin serial production of Falcon Heavy center cores, allowing its engineering, production, test, and launch staff to finally get far more accustomed to the unique hardware.

Given Falcon Heavy’s healthy and growing manifest of 5-6 launches, SpaceX will probably need to build several additional Block 5 center cores over the next several years, hopefully resulting in a more refined flow for production, testing, and refurbishment. B1057 will be an excellent candidate for the first reused Falcon Heavy center core thanks to STP-2’s lightweight nature and an extremely gentle landing trajectory. With respect to Flight 3’s schedule, Crew Dragon’s April 20th explosion means that Falcon Heavy will have Pad 39A all to itself for many months to come. Truly the epitome of bittersweet, no doubt, but it does improve the odds that Falcon Heavy’s June 22nd STP-2 launch target will hold.

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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 Full Self-Driving v14.3.6 review: a rare regression, but some bright spots

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Credit: Tesla

Tesla released Full Self-Driving version 14.3.6 last week, and after what was potentially one of the best FSD releases in v14.3.5, there has been a bit of a regression. While there are some bright spots, the changes made to v14.3.6 seem to have backtracked some behaviors.

Overall, it is hard to really complain about FSD in any sense; it has revolutionized how I travel literally anywhere. According to my self-driving app, the last time I went a day without using it was 59 days ago.

However, I think it’s also important to recognize when things are just plain bad with FSD. There are times it does truly mind-boggling things, and I’ll dive into those here. Additionally, I only had these issues on local roads, not on highways. Highway operation, generally, is always incredible other than the occasional complaint about speed or left lane camping.

With those things being said, my personal experience may not represent others’ experiences. A handful of people have said they have had a similar experience on v14.3.6, while others have said it is more than normal.

Turning Hesitancy, Inaccuracy

I’ve noticed more inaccuracy turning into multi-lane stretches of road than in any version I can remember. I’ve had at least three instances of FSD turning into a stretch of roadway that has two or more lanes, and not selecting a lane confidently as it has in past versions.

Instead, the car will drive over one of the dashed road lines, and the steering wheel will jerk back and forth before picking the lane. It should be said that it has always picked the correct lane when choosing based on the navigation, but it is still very indecisive. The steering wheel jerking is reminiscent of some of the later versions of v13.

I admit I really hate to see the steering wheel jerking come back. However, I think when Tesla releases v14.3.7, it won’t be present. When there are occurrences of it in FSD versions, it is usually resolved by the following release.

FSD Disregards Manual Turn Signals

This is my biggest bone to pick with FSD other than Navigation issues, but this one seems like it would be such an easy fix.

If Tesla is going to put the word “Supervised” on the end of “Full Self-Driving,” then when I tell the car to do something, it should do it. If I input an increase in speed by pressing the accelerator, the car will immediately respond. It does not disregard my input because it feels it is traveling at the right speed.

FSD should never disobey and turn off turn signals that the driver inputs. Trying to direct the car into the correct lane, I had initiated the left turn signal not once, not twice, but three times, with the car turning it off all three times and continuing in a lane that would end in just one block. The only solution at this point would be to zipper merge.

This goes back to the fact that self-driving’s biggest bottleneck might be rider preference. A zipper merge might have been more than reasonable, might have saved me time that I spent sitting through an additional light cycle, and might be something many drivers would do. I was in no hurry, I traditionally do not try to zipper merge because it feels inconsiderate, and lastly, the car should have just followed my input.

This caused me to disengage and drive manually the rest of the way home. Sometimes I just do not need FSD to try to pass every car it can at intersections.

Bird Braking is a Thing of the Past

The big complaint with recent versions of Full Self-Driving has been what we’ve coined as “bird braking,” which is when the car will brake suddenly as a bird flies past.

There have been zero issues with this so far in v14.3.6, which is an excellent improvement.

FSD Might Already Be Taking Note of Driver Preferences

Another thing I have noticed over the past few days is that v14.3.6 seems to already be taking my preferences with navigation into account.

This is something that is supposed to be rolling out with the Summer Update, but I have a hunch it’s already present and might have been included in this v14.3.6 build. On Friday, FSD pulled into an entrance to a local convenience store that it had never attempted to go into before.

Typically, I manually pull into this entrance because it avoids heavy cross traffic at the main entrance. FSD has always chosen that congested main entrance.

Additionally, FSD has pulled into my assigned parking spot at my townhouse community on multiple occasions with this release. This is something that used to happen ocassionally, but not consistently.

It also navigated back to the same convenience store last night, drove through crazy cars scrambling to gas pumps, navigated out of the parking lot correctly, drove me home, and, once again, parked in my assigned spot.

As previously stated, this release just seems to have a few things that need to be brought to Tesla’s attention, and also to make others who use FSD aware of some things that I’ve experienced. I look forward to the next release that will remedy these issues, just as Tesla has always done in the past.

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Musk’s massive Terafab project will get final location soon

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Credit: SpaceX

Elon Musk’s massive Terafab project, which will be the first true conglomeration between each of his major entities, is set to get its final location soon, the CEO said on Tesla’s recent earnings call.

“The Terafab, we expect to announce a location soon, and provide more details about our plans in that regard. We’ll leave that to the product, the launch announcement rather than try to squeeze it into an earnings call,” Musk said last Wednesday.

Tesla Terafab set for launch: Inside the $20B AI chip factory that will reshape the auto industry

Terafab was announced by Musk back in March and was essentially a massive, vertically integrated semiconductor manufacturing project that would provide all the chips the three companies needed for their AI initiatives without needing third-party companies.

The plant will produce over 1 terawatt of AI compute each year, and will help back up projects like Optimus, Full Self-Driving, and other AI-based projects that Musk’s companies are working on.

In April, less than a month after the project was launched, Intel announced it would join the project, contributing manufacturing expertise and consulting to Terafab as a whole. Intel is one of three chip manufacturers that produce sub-5 nanometer chips at scale. TSMC and Samsung are the other two.

However, there was no true indication of where Terafab would end up, but most believe it will likely be somewhere in Texas. Business Insider has reported that SpaceX plans to build out Terafab in Grimes County, Texas, but this is unconfirmed.

Musk confirmed recently that it would not be on Giga Texas property, as it is simply too large.

Terafab holds much of Musk’s grand ambitions for the future within its construct. It holds so much responsibility for the future and the biggest projects that Musk’s companies can imagine.

“I think this is a very big announcement and it deserves to have its own day in the spotlight and not be squeezed into an earnings call,” he said. “I do think Terafab is going to be an amazing initiative and a necessary one, and one without which we will be constrained in our ability to scale Optimus production, because we simply won’t have enough AI chips.”

He continued by stating that Terafab is necessary for scaling Optimus, which Musk said could be the biggest product of any kind of all time. “It’s crucial to solve that, and we’ll have to solve memory, logic, and packaging in order to scale Optimus.”

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Elon Musk reveals SpaceX performed secret Starship test on Flight 13

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Credit: SpaceX

SpaceX performed a secret test on a specific portion of Starship with its recent 13th test flight last week, CEO Elon Musk revealed.

Starship’s 13th test flight took place last Friday, and in many aspects, it was one of the most overwhelmingly successful launches in the project’s history.

All of the mission objectives were met without incident, both the Super Heavy Booster and Ship managed to perform safe splashdowns in the Gulf of America and the Indian Ocean, respectively, and the deployment of Starlink satellites came and went without any complications.

However, there was more on the agenda for SpaceX with Flight 13. Musk revealed an internal test of the ship’s heat shield tiles, as the space exploration company wanted to push them to the limits after previous issues.

Many noticed that Starship’s initial launch seemed to be more accelerated than normal, and that was not a mistake. Musk revealed that SpaceX decided to give Flight 13 an intentionally aggressive acceleration rate in an effort to test how well the tiles would remain attached to the ship:

SpaceX had issues with some of the heat shield tiles remaining attached early on in the Starship program. The first six test flights presented some kind of anomaly with them, so the company’s big focus with them was to figure out a way to keep them intact through the duration of the flight.

Things truly improved as Flight 10 showed that ceramic tiles generally stayed attached to the ship far better due to refined attachment, as SpaceX utilized pins instead of adhesives. Flights 10 through 13 truly showed some clear progress with the heat shield tiles, and this latest test seems to be where some real progress was noticed, especially by Musk.

The 13th Starship launch last Friday was the second with Starship V3, SpaceX’s latest and greatest iteration of the spacecraft. Goals and ambitions are getting even grander as the project continues to progress. Musk has already hinted that SpaceX will likely try to catch Starship with Flight 14.

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