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SpaceX’s next Falcon Heavy to usher Air Force into a new era of reusable rockets

Falcon Heavy center core B1057 arrives at Pad 39A around June 1st for SpaceX's STP-2 launch, NET June 24th. (USAF/SpaceX)

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After a few late-stage schedule tweaks, SpaceX’s third Falcon Heavy launch – set to deliver 24 spacecraft to a variety of orbits – is ready to usher the US Air Force into a new age of commercial rocket reuse as early as 11:30 pm ET (03:30 UTC), June 24th.

Split among the USAF, Department of Defense (DoD) research labs, NASA, NOAA, and a few US universities, STP-2’s 24 satellites will launch aboard SpaceX’s second Falcon Heavy Block 5 rocket. Both side boosters are flight-proven, having supported Falcon Heavy Block 5’s launch debut on April 11th, just 54 days ago. If all goes as planned, STP-2 will simultaneously give the USAF the data it needs to fully certify Falcon Heavy for all military launches and set the US military up to certify flight-proven commercial rockets for future launch contracts.

Signalling just how important the company feels this mission is, a dedicated STP-2 website created by SpaceX offers an excellent explanation of all aspects of the mission, from the technical to the strategic.

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. In addition, the U.S. Air Force plans to reuse side boosters from the Arabsat 6A Falcon Heavy launch, recovered after a return to launch site [RTLS] landing, making it the first reused Falcon Heavy ever flown for the U.S. Air Force.

[STP-2] will demonstrate the capabilities of the SpaceX Falcon Heavy launch vehicle and provide critical data supporting certification for future National Security Space Launch (NSSL) missions. In addition, [the Air Force Space & Missile Systems Center (SMC)] will use this mission as a pathfinder for the development of mission assurance policies and procedures related to the reuse of launch vehicle boosters.
SpaceX.com/STP-2

Following the ~June 1st arrival of Falcon Heavy center core B1057, all STP-2 launch hardware is now on site at SpaceX’s Pad 39A launch complex and nearby payload processing facilities. Although we will have to wait for official photo confirmation, SpaceX is likely in the late stages of integrating Falcon Heavy’s three boosters and upper stage, while some combination of DoD and SpaceX technicians are presumably in the middle of preparing all 24 STP-2 satellites for launch.

Falcon Heavy Flight 3’s next visible milestone will probably be the integrated rocket’s roll-out to Pad 39A for a routine static fire test, likely to occur 3-7 days prior to June 24th.

The first Block 5 version of Falcon Heavy prepares for its launch debut.
Although the center core (B1055) was not recovered intact, both side boosters (B1052 and B1053) completed a flawless landing and will be reused on STP-2. (SpaceX)

Record-breaking reusability

Incredibly, despite the schedule overhead likely added by this mission’s crucial pathfinder nature, the current June 24th launch date would permit side boosters B1052 and B1053 to simultaneously break SpaceX’s current booster turnaround record. Set in mid-2018 by B1045 on SpaceX’s last non-Block 5 launch, the record turnaround (time between launches) of 72 days would be beaten at 68 days for STP-2, barring any additional delays.

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. Both will fly again as part of the STP-2 mission. (USAF – James Rainier)

Whether STP-2’s side boosters literally beat SpaceX’s 72-day reusability record is immaterial to the actual significance of this milestone. If SpaceX can beat its old record as part of what is arguably its most complex launch ever, it’s safe to say that Block 5 reusability – particularly for gently-used boosters – is already a spectacular success. It also suggests that SpaceX technicians and launch engineers are becoming extremely familiar and comfortable with Falcon Heavy launch operations, to the extent that two boosters used on two Falcon Heavy launches could break SpaceX’s most significant reusability record.

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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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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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