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SpaceX’s Falcon 9 Block 5 set for first expendable launch with USAF satellite

Falcon 9 B1050 is seen here just after liftoff. GPS III SV01's Falcon 9 will feature no grid fins or landing legs. ☹ (Tom Cross)

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SpaceX’s most significant US Air Force launch contract yet is set to kick off with a (NET) December 18 launch of the first of 10 next-gen GPS satellites, known as GPS III Space Vehicle 1 (SV01). Thus far, SpaceX has won all five competitive GPS III launch contracts offered thus far by the USAF and – depending on Falcon 9’s performance this launch – could win several more.

Aside from contract victories, SpaceX’s first GPS III launch will be marked by yet another first for the company’s May 2018-debuted Falcon 9 Block 5 rocket. This first is not quite as desirable, though: sans landing legs and titanium grid fins, the new Block 5 booster will be expended after launch and will make no attempt to land.

At this point in time, the first official confirmation that Falcon 9 will be flying in an expendable configuration was given in a handful of comments made by Vice President of Launch and Build Reliability Hans Koenigsmann at a Dec. 5 press conference. While focused primarily on the topic at hand (SpaceX’s successful launch of the CRS-16 Cargo Dragon), members of the press managed to squeeze in a few minimally related questions which Hans graciously answered. Speaking about SpaceX’s imminent GPS III launch, Hans noted that,

“GPS is not landing a booster. It doesn’t have the landing hardware, or the majority of the landing hardware. … I looked at the booster yesterday, it’s in great shape and getting integrated in the hangar.

 

Hans also told members of the audience that he believed the expendable profile had stemmed from a customer (i.e. USAF) requirement based on a need for extra performance:

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“Regarding GPS not landing, I think this is a customer requirement to have all the performance for the mission. It’s a challenging mission.

While there was previously some doubt as to whether Falcon 9 was actually incapable of attempting a booster landing after launch, Mr. Koenigsmann’s offhand suggestion that GPS III launches would be “challenging mission[s]” makes it far more likely that the USAF’s given mission profile genuinely demands all of Falcon 9’s performance – not enough propellant will remain for Falcon 9 to attempt recovery. There is, however, still some ambiguity in Hans’ answer.

If Falcon 9 will be expended solely as a consequence of mission performance requirements despite the oddly low payload mass (~3800 kg) and comparatively low-energy orbit (~20,000 km), the only possible explanation for no attempted recovery would be the need for Falcon 9’s upper stage to perform a lengthy second burn after a long coast in orbit. However, the mission parameters the USAF shopped around for would have placed the GPS III satellite into an elliptical orbit of 1000 km by 20,181 km, an orbit that would unequivocally allow Falcon 9 to attempt a drone ship recovery.

 

The reasoning behind this is simple: SpaceX routinely recovers Falcon 9 boosters after far more energetic launches. For example, Falcon 9’s November 15th launch placed the 5300 kg Es’hail-2 satellite into an orbit of 200 km by 37,700 km, after which Falcon 9 B1047.2 performed its second successful landing on drone ship Of Course I Still Love You. A prevailing second theory for the expendable mission lies in the Air Force’s notoriously stodgy and sometimes irrational revulsion at the slightest hint of risk or change – to minimize perceived risk, the USAF could have thus demanded that SpaceX expend Falcon 9 regardless of whether it was capable of doing so.

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For GPS III SV01, it appears that only time will tell whether the satellite ends up in an orbit that can properly explain the booster’s premature demise. Given that SpaceX has a full four additional GPS III launches currently on the books, it will be a shame to see a veritable fleet of Falcon 9 Block 5 boosters tossed into the sea after just a single launch each.


For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet check out our brand new LaunchPad and LandingZone newsletters!

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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SpaceX is launching a secret spacecraft that could change how things are made in space

SpaceX’s secret disk-shaped Starfall capsule is targeting a market no reentry vehicle has cracked.

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SpaceX is targeting Tuesday, June 23 for the first flight of Starfall, a reentry capsule the company has developed almost entirely in private. The Falcon 9 launch window opens at 6:43 a.m. ET from Space Launch Complex 40 at Cape Canaveral Space Force Station, with a backup window available the same time on June 24. SpaceX has made no public announcement about the vehicle, only providing launch details. Everything known about it has come through FAA and FCC regulatory filings.

What makes Starfall different starts with its shape. Rather than the traditional cone used by Dragon and every other cargo return capsule in operation, Starfall is a flat disk that measures roughly  10.2 feet (3.1 meters) wide and just 2.5 feet (0.75 meters) tall, and weighing 4,630 pounds (2,100 kg) and capable of returning up to 2,200 pounds (1,000 kilograms) of payload from orbit. The disk geometry maximizes structural efficiency and payload volume relative to mass, and the heat shield mechanically jettisons just before splashdown, allowing recovery teams to retrieve both the capsule and the shield separately from the Pacific Ocean.

The difference with Starfall from existing competitors, such as Varda Space Industries, which has largely built the orbital manufacturing market and returns heavy payloads per flight is that Starfall’s specification is roughly 30 times more per mission, and is designed to be mass-produced and launched on either Falcon 9 or Starship. That combination of volume and launch access is something no standalone startup can replicate, and it puts SpaceX in direct competition with the companies that currently pay it to reach orbit.

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The intended market is orbital manufacturing: pharmaceuticals, protein crystals, semiconductors, and advanced optical fiber that physically cannot be produced in the presence of gravity. FAA documents describe Starfall’s long-term purpose as building a “self-sustaining commercial in-space manufacturing market” and as a potential successor to the industrial capabilities of the International Space Station, which is set to retire in the late 2020s. Military rapid global cargo delivery is a parallel application under active discussion with the Pentagon.

The reason some industries seek manufacturing in space comes down to gravity. On Earth, gravity causes materials to settle, separate, and deform during production. In microgravity, those constraints disappear.

SpaceX’s already controls launch access, which means it currently functions as the landlord for every competitor in the orbital manufacturing return space. Starfall converts that landlord position into vertical ownership, and it would no longer just carry other companies’ capsules to orbit, but rather operate the capsule, own the return logistics, and capture the service revenue directly. Viewed alongside Starlink, Colossus, and the xAI merger, Starfall fits a consistent pattern: SpaceX identifying infrastructure layers that others depend on and moving to own them outright. Orbital manufacturing return is the next layer on that list.

If Tuesday’s reentry, parachute sequence, and recovery demonstration goes as planned, the second FAA-approved test flight follows. A successful pair of demos would position SpaceX to begin offering Starfall as a commercial service, likely first to pharmaceutical and materials science customers before scaling toward the military and broader manufacturing segments.

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Tesla Semi spotted with ground truth validation equipment as launch looms

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Credit: Tesla

The Tesla Semi was spotted mounted with ground truth validation equipment as the company nears its looming launch. The Semi is Tesla’s Class 8 all-electric truck, and has been utilized in its earlier stages by many companies like PepsiCo. and Frito-Lay, who have been using it in a pilot program.

The Semi was spotted in Sunnyvale, California, and sports a typical ground truth validation unit that Tesla routinely uses on its vehicles. Ground truth validation is essentially the process of training supervised algorithms to ensure they can perform reliably. Tesla typically performs this on vehicles that are being released soon:

The Semi being spotted with this type of validation rig is important because it means the company is working on solidifying a Full Self-Driving model for its commercial vehicle offering. This would be a massive development for not only Tesla but also the logistics industry as a whole.

There are strict regulations on driving hours for commercial truck drivers, and autonomy is a way to potentially combat these issues. FSD is already a widely effective way that owners of typical passenger vehicles take stress out of travel. Even launching a semi-autonomous platform for truck drivers to use to increase safety, reduce fatigue, and increase productivity would be a huge development.

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The Semi has already proven to be an ideal solution for companies that use commercial logistics. It has increased efficiency and reduced operating costs for many companies that have been able to use it in pilot programs.

There are expected to be some bumps along the way. Tesla saw some challenges with FSD on the Cybertruck, as it had never had a vehicle with cameras at that height, so some of the features with FSD were not immediately available. Just a week ago, Tesla launched Actually Smart Summon (ASS) for Cybertruck, nearly three years after the vehicle was first delivered to customers.

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President Trump touts new Air Force One with Musk technology

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Credit: Air Force

President Donald Trump unveiled an upgraded Boeing 747-8 at Joint Base Andrews on June 19, 2026, describing the Qatar-gifted aircraft as an interim Air Force One equipped with advanced communications systems, including Starlink, Elon Musk’s SpaceX satellite internet service.

The plane, valued at around $400 million and modified for presidential use, serves as a bridge until the delayed VC-25B replacements arrive. Trump highlighted its luxury features and new technology during remarks to service members.

Trump stated:

“We have communication equipment up there that nobody’s ever seen before. It’s the highest level and, uh, including Starlink. My friend Elon is going to be very happy, but, uh, Starlink and we have, uh, four or five different sets of double and triple communications like people haven’t seen.”

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He added:

“And it represents what can happen with hard work, innovation, and aggressive timelines because we did this quickly and yet there’s never been communication like is on this plane.”

The aircraft features a redesigned red, white, and blue livery and has been outfitted with Starlink satellite connectivity alongside other secure systems.

Trump praised the plane’s uniqueness, calling it among the world’s most luxurious. The gift from Qatar and subsequent modifications have drawn attention, with the jet positioned as a solution for presidential travel. It is expected to support operations, including potential ceremonial roles such as Fourth of July flyovers.

The event marked the formal introduction of the converted jet, which will help maintain capabilities while the primary Air Force One fleet undergoes modernization. Defense observers note the inclusion of commercial satellite technology like Starlink as part of efforts to ensure resilient communications, crucial to keep the country running as the President is in the sky.

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President Trump’s comments underscored appreciation for rapid upgrades and innovation in equipping the aircraft. The plane remains a U.S. government asset and is slated for eventual transfer related to presidential library purposes after its service.

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