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SpaceX fan spots sooty Falcon 9 Block 5 booster at Kennedy Space Center

Captured by Twitter user Sideralmente (@astroperinaldo) on July 3rd, a sooty Falcon 9 booster appeared to arrive at SpaceX's Pad 39A hangar. (Twitter - @astroperinaldo)

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On July 2nd, Twitter user Sideralmente (@astroperinaldo) spotted a sooty Falcon 9 Block 5 booster arriving at SpaceX’s Pad 39A hangar facilities, currently operating as a sort of defacto refurbishment hub.

Likely a prelude to a near-term launch, SpaceX has several missions scheduled over the next few months. More likely than not, all of them will fly on flight-proven Falcon 9 boosters, now so common that launching new boosters has started to feel exceedingly rare and unusual. July 2nd’s booster spotting is also a rare (albeit slightly less rare) treat, given the general lack of access (aside from a bus tour) members of the public have to Kennedy Space Center’s operational facilities and the total lack of access they have to Cape Canaveral Air Force Station, home of SpaceX’s most active launch pad (LC-40).

CRS-18

Up next for SpaceX is Cargo Dragon CRS-18, the spacecraft’s second International Space Station (ISS) resupply mission this year. At least over the last 2-3 years, SpaceX and NASA have been fairly consistent with Cargo Dragon launches in the winter, late-spring/early-summer, and late-fall (Q1, Q2/Q3, Q4) for an average of three launches annually. 2018/2019 is no different: CRS-16 launched in early-December 2018 and CRS-17 in early-May 2019, while CRS-18 is scheduled to launch NET 7:35 pm ET, July 21st and CRS-19 is targeted for early-December 2019.

Cargo Dragon CRS-18 will carry one large and critical piece of unpressurized payload: the International Docking Adapter 3 (IDA-3). IDA-3 is seen here being loaded into Dragon’s trunk. (NASA)

Meanwhile, CRS-18 is also expected to be the first time a NASA mission launches on a flight-proven Falcon 9 Block 5 booster, potentially paving the way for NASA’s first launch on a twice-flown Block 5 booster with CRS-19 – hopefully later this year. Of course, that subsequent milestone will depend on a successful launch and landing during CRS-18. Falcon 9 booster B1056 – previously tasked with launching CRS-17 on May 4th, 2019 – is assigned to the mission and has been speedily refurbished for its next mission. Assuming the static fire goes well and there are no anomalies over the next 11 days, B1056 will launch twice in 78 days, a close second to B1048, B1052, and B1053 – all tied for first place at 74 days.

SpaceX technicians successfully retracted all four of Falcon 9 B1056’s landing legs, a first for the company’s Block 5 upgrade. (Tom Cross)

AMOS-17

Following CRS-18, SpaceX’s next launch is expected to occur soon after, launching Spacecom’s AMOS-17 communications satellite on a Falcon 9 (likely flight-proven) no earlier than early-August, although the tail-end of July is also a possibility. This mission will be extremely symbolic, owing to the fact that AMOS-17 is effectively an insurance-funded replacement for AMOS-6, destroyed on September 1st, 2016 when Falcon 9 suffered a catastrophic failure.

Thankfully, since that failure nearly three years ago, Falcon 9 has performed admirably, suffering no publicly-known failures or partial failures during its primary mission, although SpaceX has suffered two failed booster landing attempts over the same period.

Built by Boeing, AMOS-17 is likely just days away from being shipped to Florida to prepare for launch, assuming it’s not already on site. (Boeing)

It’s possible that the mystery booster spotted above is meant for AMOS-17, although that’s far from certain. Based on an image showing the core number, it is almost certainly B104X, while the second digit could easily be a 7 or a 9. If the booster in question is B1047, the odds are much better that it’s wrapping up refurbishment and waiting at 39A for CRS-18 to launch before heading to LC-40.

Starlink?

On the other hand, if the booster in question is B1049, it can be all but guaranteed that AMOS-17 will not launch on it, the reason being that – quite literally burned by its last experience with Falcon 9 – Spacecom probably doesn’t want to be the first SpaceX customer to launch on a thrice-flown booster. At the same time, SpaceX is probably exceptionally conscious of the need to ensure mission success and has no interest in adding risk to the AMOS-17 mission profile, no matter how minor.

SpaceX’s first 60 Starlink satellites – acting as a massive beta test – coast in orbit before being deployed from Falcon 9’s upper stage. (SpaceX)

B1049 launched for the third time in support of SpaceX’s first dedicated Starlink launch on May 23rd, known internally as Starlink v0.9. At this point in time, B1046.3 is believed to be assigned to Crew Dragon’s in-flight abort (IFA) test, expected no earlier than Q4 2019. B1048.3’s status is unknown since the rocket successfully completed its third launch in February 2019. With B1049’s newfound history as the first SpaceX booster to launch on a completely internal mission, it would make a lot of sense for SpaceX to reuse B1049 for the next Starlink mission.

Simultaneously, SpaceX could demonstrate the first launch of a thrice-flown Falcon 9 booster without pushing that risk onto customers, opening up B1048 and future thrice-flown boosters for near-term commercial missions. A step further, this would set SpaceX up perfectly to use internal Starlink missions as full-fidelity demonstrations of booster reuse milestones, going from the four launches to five, six, seven, and beyond.

Falcon 9 booster B1049.3 rests horizontally at Port Canaveral after completing its third successful launch. (Pauline Acalin)

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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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