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Falcon Heavy Flight 2. The booster in the middle - B1055 - was effectively sheared in half after tipping over aboard drone ship OCISLY. (Pauline Acalin) Falcon Heavy Flight 2. The booster in the middle - B1055 - was effectively sheared in half after tipping over aboard drone ship OCISLY. (Pauline Acalin)

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SpaceX Falcon Heavy booster tips over on drone ship, returns to port in pieces

Falcon Heavy Flight 2. The booster in the middle - B1055 - was effectively sheared in half after tipping over aboard drone ship OCISLY. (Pauline Acalin)

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SpaceX’s first Falcon Heavy Block 5 center core (i.e. booster) has completed a bittersweet return to shore aboard drone ship Of Course I Still Love You after apparently breaking in half during a wave-induced tumble.

Local maritime and spaceflight fans Julia Bergeron and Stephen Marr were first to document the condition of the SpaceX rocket as it passed through the mouth of Port Canaveral. Although the lighting conditions were far from optimal, photos indicate that the Block 5 center core suffered a near-surgical removal of everything above its kerosene (RP-1) propellant tank. In other words, the liquid oxygen (LOx) tank and interstage are nowhere to be found, while Falcon Heavy B1055’s octaweb, nine Merlin 1D engines, landing legs, and maimed RP-1 tank are all safely resting on OCISLY’s deck.

The port arrival of B1055’s severed aft section is not exactly the happiest ending to the story of Falcon Heavy Flight 2 but the booster’s demise will reportedly have no impact on SpaceX’s 2019 launch manifest. That includes Flight 3 of Falcon Heavy, scheduled to launch with both of Falcon Heavy’s flight-proven side boosters as early as late June. Thankfully, SpaceX has built a second brand new Falcon Heavy center core for the critical US Air Force mission, known as STP-2.

Likely to be booster B1057, that fresh center core should have no difficulty supporting Falcon Heavy’s third launch, although SpaceX will probably ensure that the drone ship’s robotic recovery robot is Falcon Heavy-compatible this time around.

The first Block 5 version of Falcon Heavy prepares for its launch debut.
It can now be said that approximately two and half of Falcon Heavy Flight 2’s three Block 5 boosters were recovered successfully. (SpaceX)

According to SpaceX CEO Elon Musk, the cause of this incident is easily traced back to a combination of bad luck and the simple fact that OCISLY’s Octagrabber had yet to be outfitted for Falcon Heavy center cores. It’s unclear what prevents Octagrabber from interfacing with the custom boosters, but it likely involves the bulky mechanisms they use to transfer the thrust of both side boosters and safely push them away during booster separation. Those mechanisms – a combination of matte black polygons and cylinders and clockwork-like blocks – are easily visible in the photo above.

Some minor subassemblies can probably be salvaged from the badly damaged aft section of B1055 but the booster’s nine Merlin 1D engines are likely the only major recoverable hardware. Even then, it appears that the nozzles of at least two of those Merlin 1Ds were damaged by B1055’s tumble.

The successful recovery of B1055’s engine section should still give SpaceX’s recovery and refurbishment engineers their first hands-on post-flight analysis of a center core’s complex connection and separation mechanisms. Having suffered through an exceptionally hot and fast reentry, the condition of those mechanisms and the booster’s octaweb heat shield will hopefully be able to offer valuable insight into their performance at the edge of Falcon’s survivable flight envelope.

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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 eyes supply partners for Optimus mass production

Tesla certified three Chinese suppliers for Optimus mass production, signaling its robot timeline is accelerating.

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Concept rendering of Tesla Optimus in mass production

Tesla’s robotics team traveled to Ningbo, in China’s Zhejiang province, on September 16 and spent the following day auditing component suppliers for Optimus, according to a Bloomberg report cited by RobotAIGeek. The visit moved three manufacturers from provisional status to certified mass production partners: Tuopu Group, which handles actuators and chassis components, Ningbo Joyson Electronic, a sensor supplier, and Zhejiang Sanhua Intelligent Controls, which builds thermal management systems. All three already supply parts to Tesla’s electric vehicles, and the audit reportedly came with fresh orders that supply chain reports put at an initial batch of roughly 5,000 units.

Tuopu, Joyson, and Sanhua built their manufacturing base serving the automotive industry, where tolerances and volume requirements are already close to what a mass produced humanoid robot demands. Sanhua in particular has history here. Teslarati reported last October that the company had received a roughly $685 million order for linear actuators tied to Optimus, a volume industry watchers estimated could cover around 180,000 robots once production ramped.

Supply chain reports tied to this week’s audit put Tesla’s near term production goal at about 1,000 Optimus units a week by late September, rising to 2,000 to 2,500 units a week by the end of the year. That pace would put real weight behind the timeline Tesla has been building toward since May, when it wound down Model S and Model X production at Fremont to convert that floor space into a dedicated Optimus line targeting one million units annually. JPMorgan analysts who toured the factory in August confirmed the conversion took roughly four months, a pace Musk has called unprecedented for a facility that size.

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

Fremont is only the first phase. A second, larger Optimus plant is rising at Gigafactory Texas, where drone footage shared by Joe Tegtmeyer last week showed the structural steel nearing completion on the north end of the building. Tesla has said that facility is meant to eventually support production of up to 10 million units a year, though volume output there is not expected before 2027.

Commercial sales of Optimus are still targeted for the second half of 2027, but production is expected to start well before then. JPMorgan analyst Rajat Gupta has said Tesla’s “Optimus Academy” program, which uses early units to collect real world training data inside Tesla’s own facilities, is expected to be running later this year. Bloomberg Intelligence analyst Ian Ma described the Ningbo audits as “a positive commercialization signal for China’s humanoid supply chain,” noting that sentiment could improve further if the visit leads to confirmed supplier nominations and larger orders. The Solactive China Humanoid Robotics Index rose about 1.4% on the news, though it remains down roughly 30% for the year.

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Elon Musk’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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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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