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SpaceX’s first astronaut-proven rocket returns to dry land

Its Falcon 9 emblem filed off and replaced with a NASA meatball, SpaceX has successfully returned the first 'astronaut-proven' Falcon 9 booster to dry land after the rocket's Crew Dragon launch debut. (Richard Angle)

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Three days after becoming the first privately-developed rocket in history to launch humans into orbit, SpaceX’s first astronaut-proven Falcon 9 booster has safely returned to dry land.

Although the sheer importance of SpaceX’s flawless astronaut launch debut and space station arrival can’t be exaggerated, the fact remains that the vast majority of the company’s orbital missions are centered around the affordable launch of satellites and other uncrewed payloads. All of those launches need Falcon boosters, too, and Crew Dragon’s Demo-2 mission has come at a time when SpaceX’s fleet of flightworthy rockets is the smallest it’s been in at least 18 months.

Significantly thinned by two failed Falcon Heavy center core recoveries and the loss of four boosters in 2020 alone (two intentional, two less so), SpaceX’s booster fleet has dropped from as many as ten to as few as two in just 13 months. Thankfully, B1058’s successful May 30th landing and June 2nd return adds a third booster to SpaceX’s immediately-available rocket fleet. On the horizon, two additional unflown boosters are in the late stages of preparation for their separate launch debuts – no earlier than (NET) June 30th and August 30th, respectively. With a little luck, SpaceX’s fleet of flight-proven boosters will soon have grown nearly three-fold in about as many months.

SpaceX’s first astronaut-proven rocket booster – designed and built by the private company – has safely returned to dry land. (Richard Angle)

At the moment, SpaceX’s own Starlink satellite internet constellation is by far the biggest source of demand for SpaceX rockets – particularly the flight-proven boosters that allow the company to perform those launches at an unprecedented cost. Over the last 12 or so months, thanks to the spectacular success of Falcon 9 Block 5 reusability, SpaceX has substantially cut booster production at its Hawthorne, California headquarters, thus far dedicating the last six boosters produced to strict, high-profile missions for NASA and the US military.

In other words, while SpaceX has technically had three unflown Falcon 9 boosters – B1058, B1060, and B1061 – more or less ready for flight for months, their first launches have to be reserved for a select few customers that still have reservations about the company’s flight-proven rockets. With its first reserved mission – Crew Dragon’s orbital astronaut launch debut – now out of the way, gently-used Falcon 9 booster B1058 can thankfully enter the greater SpaceX fleet and begin preparing for its next launch.

Falcon 9 B1058 landed just shy of nine minutes after lifting off with NASA astronauts Bob Behnken and Doug Hurley on May 30th. (SpaceX)
The booster safely returned to Port Canaveral aboard drone ship Of Course I Still Love You (OCISLY) three days later. (SpaceX)
(Richard Angle)

Thanks to the fact that booster B1058’s first flight incurred a relatively gentle atmospheric reentry and landing, it could potentially be turned around for its next launch extremely quickly. With three Starlink launches scheduled in June alone and the first expected to launch as early as 9:25 pm EDT (01:25 UTC), June 3rd, SpaceX may actually have to refurbish B1058 far more quickly than any booster before it. SpaceX currently has two Falcon 9 boosters (B1049 and B1051) available for Starlink launches. B1049 is set to launch this week, while B1051 flew its fourth mission just six weeks ago. Based on SpaceX’s current record of 62 days between launches of the same booster, B1051 could be ready for its fifth mission by late June.

In other words, unless SpaceX brings flight-proven Falcon Heavy side booster B1052 or B1053 out of retirement later this month, the company is going to have to break its booster turnaround record by a huge margin with B1049 or B1058. SpaceX certainly has a funny way of resting on its laurels.

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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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Investor's Corner

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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