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SpaceX Falcon Heavy rocket passes static fire test three years in the making

The first Falcon Heavy rocket is pictured during its own static fire test in early 2018. (SpaceX)

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After knocking out some figurative cobwebs, SpaceX has test-fired a Falcon Heavy rocket for the first time since June 2019.

Shortly before the static fire, NASASpaceflight’s Thomas Burghardt reported that Falcon Heavy’s first launch in 40 months – a mission for the US Space Force known as USSF-44 – had slipped from October 28th and October 31st to no earlier than (NET) 9:40 am EDT (13:40 UTC), Tuesday, November 1st. USSF-44 will be Falcon Heavy’s fourth launch since February 2018.

During its 10-second October 27th static fire, Falcon Heavy – the most capable rocket currently operational – appeared to ignite all 27 of its first stage’s Merlin 1D engines, likely producing up to 2350 tons (5.18 million lbf) of thrust. Only three liquid-powered rockets (N1, Saturn V, & Energia) and one rocket augmented by solid rocket boosters (the Space Shuttle) have produced more thrust at sea level, and the most recently active of those four vehicles (NASA’s Space Shuttle) was permanently retired in 2011.

NASA’s Space Launch System (SLS) rocket will retake the crown when it (hopefully) debuts later this year, but Falcon Heavy will remain the most powerful commercially-available rocket until SpaceX’s own Starship debuts. After Starship debuts later this year or early next, Falcon Heavy will continue on as the second most powerful commercial rocket for the indefinite future.

After more than three years of downtime, SpaceX unsurprisingly appeared to run into minor issues while preparing Falcon Heavy for a full wet dress rehearsal and static fire. SpaceX rolled the rocket – sans payload fairing – out to the launch pad late on October 25th, at which point the launch target had already slipped to October 31st. Falcon Heavy then sat horizontally for about 30 hours before SpaceX raised it vertical and fully attached the rocket and transporter/erector to the pad’s ground systems.

Another 12 hours of work later, SpaceX was ready to begin static fire test operations, and Falcon Heavy fired up at 8 pm EDT on October 27th, 50 hours after it rolled out. During Falcon 9’s most recent satellite launch out of Pad 39A, the rocket lifted off about 30 hours after rollout. While preparing for Falcon Heavy Block 5’s first launch (Flight 2 overall) in April 2019, the rocket went vertical 12 hours after rollout – 18 hours faster than Flight 4. Ahead of Flight 3 in June 2019, Falcon Heavy completed a static fire test 25 hours after rolling out – 25 hours faster than Flight 4.

Falcon Heavy Flight 2 – the first Block 5 version of the rocket – sits horizontally at Pad 39A. (Pauline Acalin)
Falcon Heavy Flight 3. (NASA)

Before it can launch, Falcon Heavy will have to return to LC-39A’s hangar to have its fairing (containing two classified USSF-44 satellites) installed and then return to the pad, repeating the rollout process. Falcon Heavy Flight 3 holds the record (5d 4h) for the shortest gap between a static fire and launch. Falcon Heavy’s updated launch target is 4 days and 14 hours after its static fire, meaning that SpaceX will have to break that record to launch USSF-44 as planned.

Update: The USSF-44 payload fairing – satellites safely encapsulated inside it – headed to Pad 39A less than four hours after Falcon Heavy Flight 4’s static fire.

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Regardless, with a successful static fire under its belt, Falcon Heavy’s fourth launch is now all but guaranteed to occur within the next 5-10 days. The rocket’s fifth launch – carrying ViaSat’s first ViaSat-3 communications satellite – could follow as early as December 2022, and another four Falcon Heavy launches are currently scheduled between January and August 2023.

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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Cybertruck

Tesla Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

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

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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Elon Musk

SpaceX has solved Starship’s biggest challenge, Elon Musk says

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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