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SpaceX spotted hot-fire testing Falcon 9 Block 5 ahead of its first reflight on August 7

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Less than three months after SpaceX debuted its upgraded Falcon 9 Block 5 rocket, the company is set for an unexpectedly sudden inaugural reuse of the first highly reliable and reusable rocket to roll off of the Hawthorne, CA assembly line. Falcon 9 booster 1046 (B1046) is now targeting 1:18 AM EDT, August 7 for its second launch.

Confirmed by visual observation of a sooty Block 5 booster vertical on Cape Canaveral’s Pad 40, this reuse will be just two weeks away from beating SpaceX’s booster turnaround record of 72 days.

On the ground to visually confirm plans for the historic reuse, Teslarati photographer Tom Cross also managed to capture an intriguing propellant loading and abort test, where SpaceX appeared to intentionally abort a ‘launch’ attempt after rapidly loading a full complement of liquid oxygen (LOX) and rocket-grade kerosene (RP-1).

While not 100% clear why this testing was done today, an extensive understanding of Falcon 9 Block 5’s behavior during propellant late-load and launch abort scenarios are both critical for the reliable operation of the upgraded rockets and invaluable for the first Crew Dragon launches later this year and early next, the latter with astronauts on board. With humans atop the rocket, a deep understanding of the vehicle’s behavior during a wide range of off-nominal scenarios is more critical than ever, be it required by NASA or simply a side effect of due diligence on behalf of SpaceX.

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https://twitter.com/_TomCross_/status/1025074341040533504

A new era of reusable rockets

Regardless, the main focus of this mission is to launch a payload for Indonesian operator PT Telkom Indonesia, in this case a ~5800 kg (12800 lb) geostationary communications satellite known as Merah Putih (formerly Telkom 4). On the SpaceX side of things, this mission is absolutely critical for the company’s future – it will mark the (hopefully) successful inaugural reuse of a Falcon 9 Block 5 booster, the first of many dozens or even hundreds to come over the next several years if SpaceX’s can make good on its aspirations.

While not immensely impressive in the sense that B1046’s refurbishment took ~85 days to Block 4’s record 72-day turnaround, that cursory conclusion is far from accurate. The record turnaround with Block 4 booster B1045 was essentially the culmination of more than a year of experience with nearly a dozen Block 3 and Block 4 Falcon 9 reuses. While that experience definitely transferred in part to SpaceX’s first attempt at reusing Falcon 9 Block 5 (and especially so with the actual design of its reusability-focused upgrades), it’s worth noting that the first reuses of Falcon 9s averaged booster turnaround times of 180-250 days, nearly double or triple the time between Block 5’s first-ever launch and that same booster’s first reflight.

 

Even still, B1046’s debut launch, landing, and refurbishment were wholly unique considering that SpaceX – according to Elon Musk – conducted an extensive “teardown” analysis of the pathfinder rocket after it was transported from the drone ship back to one of the company’s Cape Canaveral refurbishment facilities. It’s very likely the case that that teardown was one of the most extensive SpaceX has done with a recovered rocket, couched on the fact that the company’s future is wholly balanced on Falcon 9 Block 5’s success and ease/efficiency of reusability.

The first Block 5 Falcon 9 lifts off on May 4, 2018. This same booster is set to be reused roughly 13 weeks after its debut, and just completed its second on-pad static fire on August 2nd. (Tom Cross)

That critical teardown process likely took anywhere from 30-60 days, if not simply as long as needed to do it right, after which the rocket was fully reassembled and transported to SpaceX’s Launch Complex 40 (LC-40). Roughly eight days after it arrived at LC-40, B1046 rolled out to the pad’s launch mount, went vertical, and completed a series of tests (including static fire) on Thursday (8/2) afternoon. The static fire was confirmed by a few observers, while Tom Cross captured the first unequivocal proof that the rocket is sooty (and thus B1046).

This moment may seem small on the scale of SpaceX’s many towering achievements, but it will very likely become a fundamental keystone in the future history of affordable access to space.

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prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet (including fairing catcher Mr Steven) 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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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.

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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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Investor's Corner

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.

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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.

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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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