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SpaceX to fly ‘hybrid’ Falcon 9 with Block 4 and 5 stages on June 4 launch
According to SES chief technical officer Martin Halliwell, SpaceX intends to “thread the needle” with a unique hybrid Falcon 9 launch of his company’s SES-12 communications satellite on June 4th.
In the case of this launch, Halliwell’s “needle” refers to unsavory weather conditions present at Florida’s Cape Canaveral launch facilities, although weather appears to be improving significantly over the next few days. Originally scheduled for launch on May 24, SES-12 was pushed to May 31, June 1st, and finally June 4th, according to a tweet from SpaceX earlier this morning. Minor difficulties with hardware in the Falcon 9’s Block 5 upper stage required additional troubleshooting and were ultimately magnified by the fact that Cape Canaveral Air Force Station’s range is technically supposed to be closed for launches at the moment, a shutdown of two or so weeks meant to allow the station’s range to conduct routine maintenance and install upgraded hardware (radar, meteorology, helicopter maintenance, avionics, software, etc).
https://twitter.com/_TomCross_/status/1002217744421609474
As such, it’s unlikely that the minor upper stage hardware issues referenced by SpaceX literally entailed a 72 hour delay. In fact, it’s fairly unique for the Eastern Range to go so out of their way to accommodate launches well within a closure period – May 28 to June 9 – scheduled months in advance. Once SpaceX’s SES-12 mission is completed, the range will likely try to complete necessary maintenance ops.
Falcon 9 B1040 returns to Landing Zone-1 after launching the X-37B spaceplane. It’s second and final flight will be with the SES-12 communications satellite. (SpaceX)
In a press conference hosted by the satellite operator SES, CTO Martin Halliwell further discussed some of the more technical aspects of the imminent SpaceX launch, waxing poetic about the particular flight-proven rocket’s fusion of a Block 4 Falcon 9 first stage and a Block 5 upper stage. With its “monster” Block 5 Merlin Vacuum engine, Halliwell noted that the extra performance provided by the upgraded second stage’s higher thrust, the expendable first stage launch profile, and the removal of its grid fins and landing legs could enable as much as seven years of additional operational life for the massive communications satellite.
Although the CTO did not explicitly confirm it, his comments indicate that this launch of the Block 5 upper stage – likely the third after Falcon 9 Block 5’s May 11 debut – may operate at 5% higher thrust for the first time, something briefly discussed by SpaceX CEO Elon Musk in a press call before the Block 5 debut. In that call, the CEO stated that the upgraded vacuum version of Merlin would fly with its thrust downrated by 5% to avoid risking a customer’s payload while ensuring that the hardware and software upgrades were functioning as intended. It appears that the data and experience provided by the Bangabandhu-1 mission’s downrated thrust profile was extremely encouraging, leading SpaceX to open the throttle a bit more with the SES-12 mission, so to speak.
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- Falcon 9 1046’s Block 5 upper stage shown on its May 11 debut launch with Bangabandhu-1. SpaceX’s rockets already provide rich telemetry live to the company’s launch controllers. (SpaceX)
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- Falcon 9 Block 5 completed its first launch on May 11, carrying the Bangabandhu-1 communications satellite to geostationary transfer orbit. (Tom Cross)
Falcon 9 B1040, the reused booster tasked with launching the second stage and satellite above Earth’s atmosphere, previously flew on September 7, 2017, launching the USAF’s secretive X-37B spaceplane into low Earth orbit. Teslarati photographer Tom Cross will capture the booster’s last flight around 12:30am on June 4th.
A California radiologist who drove his Tesla Model Y off a 250-foot cliff in an attempt to kill his family has had his charges dismissed after doctors say he is “doing well” in a mental health program.
Dharmesh Patel was charged with three counts of attempted murder in connection with a January 2023 crash where he drove his Tesla off a cliff, injuring his wife and two children, aged 7 and 4 at the time.
Patel drove the Tesla off Devil’s Slide in California, an area that is extremely rough to the point that investigators and rescuers expected the worst when arriving at the scene for the first time. Patel supposedly had schizoaffective disorder, according to Deputy District Attorney Dominique Davis.
Shockingly, Patel’s wife, who was in the vehicle, testified that she did not want her husband to be prosecuted, noting that their children missed their father and they wanted him to come back home. Patel’s attorney argued, “not everyone who commits a crime is a criminal.”
Doctor who took Tesla off cliff gets support from unlikely person
A three-day trial in Mental Health Diversion Court ruled in Patel’s favor, which kept him out of jail and instead on house arrest. He was admitted to a Mental Health Diversion Program, which he successfully completed, the Associated Press reported. San Mateo County District Attorney Steve Wagstaffe said the judge was “required by law” to dismiss the charges:
“If the person who’s given mental health diversion follows the treatment plan, there’s nothing that can be done, and at the end of the two years he gets it wiped out of his record.”
Wagstaffe said he has argued, along with other DAs in California, to have attempted murder removed from the list of charges eligible to be dismissed due to mental health diversion programs.
Patel had the charges officially dismissed on Monday; his wife waited for him as he left court and they departed the building together, according to Mercury News. Patel surrendered his California medical license in December.
The crash has been one of the best examples of Tesla’s incredible engineering, which has saved four lives in this particular instance. The car was totalled but kept the four human beings alive and safe, which is something that many referred to as “an absolute miracle.”
A common misconception of anti-EV proponents is that the batteries used in the vehicles are detrimental to the environment and that they cause more waste than they are worth. But a look at Tesla’s battery recycling efforts last year shows the company is doing more than ever to recover materials and give portions of the cells a second life.
Tesla reported a significant milestone in its sustainability efforts last year, with battery recycling volumes rising 20% compared to 2024. According to the company’s 2025 Impact Report, Tesla recycled over 14,000 metric tons of battery material through a combination of in-house processing at its Gigafactories and collaborations with third-party recycling partners.
Tesla: “In 2025, we recycled over 14,000 metric tons of battery material through a combination of in-house processing and through our network of recycling partners.”
That’s equivalent to 46,000 long-range battery packs, a +20% increase from 2024. pic.twitter.com/TC3Nz7Kaqf
— Sawyer Merritt (@SawyerMerritt) July 7, 2026
This amount of recovered material is equivalent to the resources needed to produce approximately 46,000 long-range battery packs. The increase reflects growing operational scale as Tesla’s global vehicle fleet expands and more batteries reach end-of-life or manufacturing scrap becomes available for processing.
Tesla and Battery Recycling
Battery recycling forms a core part of Tesla’s circular economy strategy. The company designs its batteries for longevity, often exceeding 200,000 miles of driving, and prioritizes repairs, remanufacturing, and second-life applications before full recycling.
Once packs are decommissioned, Tesla ensures 100% are recycled with no materials sent to landfills. This approach recovers critical metals including lithium, nickel, cobalt, and copper, which can be refined and reused in new battery production.
Tesla has advanced hydrometallurgical recycling processes capable of achieving recovery rates up to 98% for key battery metals. These methods are more efficient and environmentally friendly than traditional pyrometallurgical techniques, reducing energy use and enabling higher-purity materials suitable for direct reintegration into battery manufacturing.
Tesla co-founder JB Straubel confirms Redwood’s battery recycling operations are already profitable
In-house capabilities are supplemented by a network of specialized partners, creating a robust system that handles both production scrap and end-of-life packs.
The environmental and economic benefits are substantial. Recycling reduces reliance on virgin mining, lowers the carbon footprint associated with raw material extraction and processing, and helps stabilize supply chains for critical minerals amid rising global EV demand. As millions of Tesla vehicles age, the volume of recyclable material is expected to grow significantly in the coming years.
This 20% year-over-year growth demonstrates the effectiveness of Tesla’s investments in recycling infrastructure and technology. It positions the company as a leader in addressing one of the automotive industry’s major sustainability challenges. Continued innovation in battery design for easier disassembly and higher recyclability will further enhance these efforts.
Overall, Tesla’s progress in 2025 highlights how scaling recycling operations supports both environmental goals and long-term business resilience in the transition to electric mobility. As the EV market matures, such closed-loop systems will become increasingly vital for sustainable growth.
Tesla has spent years trying to engineer its way out of the automotive paint shop, one of the most expensive, space-consuming, and environmentally costly steps in vehicle manufacturing. With the Cybercab, Tesla confirmed on X this week that a new reaction injection molding process will embed color directly into the panel itself during production.
“Our new reaction injection molding (RIM) process shrinks Cybercab paint cycles from hours to minutes. This cuts those parts’ manufacturing and supply chain emissions by 35% and eliminating 100% of paint volatile organic compounds (VOCs) emitted in traditional paint methods.” noted Tesla.
While the RIM process isn’t necessarily new and has existed since the 1960s, what makes Tesla’s application notable is how it is being used specifically for exterior body panels that traditionally required a separate paint process after forming.
Tesla’s RIM approach integrates the color directly into the panel material during the molding process itself. The pigment is part of the polymer mix injected into the mold, meaning the panel comes out of the mold already colored, with no separate paint application required. The clear coat or protective layer can be applied at the mold stage or through a much faster post-process than traditional multi-stage painting. Tesla claims this compresses what was a multi-hour paint cycle into minutes per panel.
Tesla’s obsession with killing the paint shop is one of the most consistent threads running through the company’s manufacturing philosophy going back years. As far back as 2018, Musk was trimming paint color options to simplify production, tweeting at the time: “Moving 2 of 7 Tesla colors off menu on Wednesday to simplify manufacturing.” Two years later, in a 2020 Automotive News interview, Musk laid out his broader vision, saying he believed Tesla factories could one day be 1,000 times more efficient than conventional plants, and pointing to the paint shop as one of the biggest sources of waste, cost, and complexity. The Cybertruck was the most extreme expression of that thinking. Tesla chose an unpainted stainless steel exterior partly because it would eliminate the need for a $200 million paint facility at Gigafactory Texas. The stainless approach proved harder and more expensive than anticipated, but the underlying ambition never changed. The Cybercab is what happens when that same ambition meets a manufacturing process that delivers on it.
Radiologist who drove Tesla off cliff has attempted murder charges dismissed
Tesla battery recycling efforts increased 20 percent last year
