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SpaceX to test last old-gen Falcon 9’s orbital upper stage lifespan tonight

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SpaceX Falcon 9 B1045 is just hours away from completing its second and final mission, a launch that will also signify a swan-song for the reusable rocket company’s Block 4 and older boosters. Not one to let an opportunity go to waste, Elon Musk’s space company intends to do a long coast demonstration of the orbital upper stage once the reused Cargo Dragon spacecraft separates.

Jessica Jensen, SpaceX’s Director of Dragon Mission Management, spoke among a panel of CRS-15 stakeholders on the morning of June 28 and spoke evident pride and confidence in the company’s progress up to this point, with respect to both the mission at hand and SpaceX’s achievements more generally. CRS-15, the third flight-proven Dragon and Falcon 9 launch, is a fitting mission for SpaceX to bring to a close their H1 launch manifest (the 12th of 2018), mainly due to the impressive fact that more than two-thirds of the boosters launched this year have been flight-proven.

Falcon 9 B1045 before its first launch, carrying NASA’s TESS exoplanet observatory, in April 2018. (Tom Cross)

As Jensen rightfully noted, SpaceX completed its first-ever reuse of a recovered Falcon 9 booster scarcely 15 months ago in March 2017, a period in which SpaceX has since completed 26 missions, recovered 16 Falcon 9 and Heavy boosters, and successfully launched 12 flight-proven rocket boosters. At the current rate of launch, SpaceX is likely to smash its previous annual cadence record – 18 in 2017 – with anywhere from 24 to 28 launches this year, with CRS-15 marking a dozen missions in the first half of the year, if successful. As such, simply the launch frequency in the first six months would bring SpaceX to 24 completed missions this year. A slight uptick, perhaps as a result of the rapid reusability of new Block 5 boosters, might allow SpaceX to squeeze in several additional missions.

Falcon 9 B1045 and it’s Cargo Dragon C111 prepare for their second flights on June 29. (Tom Cross)

Critically, Jensen also noted that B1045’s final launch will be significant for a reason other than the fact that it nearly halved the previous record for Falcon 9 booster refurbishment, an accomplishment she ceded to the skill and growing experience of SpaceX’s rocket refurbishment teams of engineers and technicians. Aside from that growing expertise, she stated that

“[CRS-15] will also be the final Block 4 configuration of a Falcon 9 booster that SpaceX flies, so all the boosters from here on out will be the Block 5 version.”

Barring unforeseen design flaws, Falcon 9 Block 5 has the potential to be a game-changer, perhaps allowing SpaceX to finally realize a long-term goal of dramatically lowering the cost of access to orbit with new reliable, reusable rockets. Reported by NASASpaceflight.com to be flying aboard a Block 4 booster, something also confirmed to Teslarati through a separate source, it’s not 100% clear if Jensen’s blanket statement included the upcoming in-flight Crew Dragon abort test, scheduled sometime after the upgraded Dragon’s first launch in late 2018. Regardless, she is fully correct in the sense that all future commercial SpaceX launches after CRS-15 will quite definitively fly aboard Falcon 9 and Heavy Block 5 rockets.

Flight-proven Cargo Dragons a new norm for SpaceX

Meanwhile, the specifics of CRS-15 mirror SpaceX’s two most recent International Space Station resupply missions, both of which simultaneously flew flight-proven orbital Cargo Dragon spacecraft and flight-proven Falcon 9 boosters, leaving just the second stage and Cargo Dragon trunk to be expended. As a taste of the future SpaceX fully intends to realize, the spectacle of these CRS missions is not only undeniable but demonstrates a newfound confidence in commercial reusable rockets growing within NASA, an agency that SpaceX would quite simply not be here today without.

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https://twitter.com/_TomCross_/status/1012490324646748163

After CRS-15, SpaceX has another five flight-proven Cargo Dragon missions left on their CRS-1 contract, after which the updated CRS-2 contract will take over, replacing the old Cargo Dragon with an upgraded cargo version of SpaceX Crew Dragon, also known as Dragon 2. CRS-2 launches are currently scheduled to begin sometime in 2020.

Finally, reminiscent of Falcon Heavy’s spectacular debut launch, Falcon 9’s upper stage “will be doing a long coast demonstration [after Cargo Dragon separates from the rocket]”. Jensen was unable to go into more detail here, but it can be safely presumed that the S2 coast test is either related testing for upper stage reusability or is being used as an opportunity to further demonstrate on-orbit coast capabilities to the US Air Force and/or NASA, a feature that is necessary for certain national security and interplanetary missions.

Follow us for live updates, peeks behind the scenes, and photos from Teslarati’s East and West Coast photographers.

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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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Tesla’s dedicated Optimus factory construction officially underway at Giga Texas

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(Credit: Tesla)

Tesla’s dedicated factory for building up to ten million Optimus units is officially under construction at Gigafactory Texas.

Drone footage released on May 27 by Giga Texas observer Joe Tegtmeyer captures the significant milestone of the first steel structure officially standing at Tesla’s new Optimus factory on the North Campus of the facility.

Phase two of land reclamation is advancing steadily, and the progress will let the new building extend nearly the full length of the main Giga Texas factory, potentially exceeding 4,000 feet, while measuring somewhere between 50 and 70 meters narrower. Extensive foundation work is proceeding as well.

This facility forms a central element of Tesla’s broader North Campus expansion at Giga Texas. The project will add more than 5.2 million square feet of new industrial space. It sits alongside other advanced developments, including a Terafab for next-gen AI chips. The scale reflects Tesla’s commitment to transforming humanoid robotics into a core pillar of the company’s future.

Musk has said that Optimus will be the biggest product in the world on several occasions. He believes it will be Tesla’s biggest valuation contributor.

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Tesla prepares to expand Giga Texas with new Optimus production plant

Tesla plans to build about 10 million robots at the site annually once it is completed, which would be about 27,000 units each day.

The Optimus plant at Giga Texas is part of Tesla’s phased strategy for Optimus manufacturing. In an effort to start production of the robot well before the Giga Texas plant is complete, Tesla ended production of the Model S and Model X vehicles, which were built in Fremont, California, to make way for initial Optimus manufacturing efforts.

Production there will start in either July or August of this year, and early units will support internal factory tasks while the team gathers real-world data to refine processes. The Gigafactory Texas facility will house a second-gen production line. It targets high-volume output starting in Summer 2027.

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Musk has repeatedly described Optimus as potentially more valuable than Tesla’s entire vehicle business. Current versions are already completing minor tasks around various facilities, while Tesla continues to refine its abilities and add new features.

Tesla’s total investment could reach several billion dollars. Significant challenges lie ahead, including the creation of an entirely new manufacturing ecosystem, the refinement of AI systems for dependable autonomy, and the development of reliable supply chains for actuators, sensors, and other components.

Nevertheless, the visible progress at Giga Texas highlights Tesla’s capacity to translate ambitious concepts into physical reality.

Tesla’s Optimus factory stands as much more than a simple expansion project, as it is quite literally the second phase of what could potentially be the biggest product ever. With construction beginning, 2027 is poised to become a transformative year for Tesla, as it evolves even further from an electric vehicle leader into a pioneer of intelligent, general-purpose machines.

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Tesla teases going Plaid Mode with the Model 3

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Credit: Tesla

Tesla Vice President of Vehicle Engineering, Lars Moravy, recently revealed the company has thought about introducing a Plaid powertrain on the Model 3, but there could be some challenges involved.

On the Ride the Lightning podcast, Moravy revealed that he thinks about a Plaid Model 3 “all the time,” and it certainly has a place in Tesla’s potential lineup of future vehicles.

Now that the Plaid powertrain is technically defunct due to the newfound absence of the Model S and Model X, Tesla could find a way to reintroduce the lightning-quick trim level to its mass-market vehicles.

But there are going to be some challenges with it. Moravy said that the Model 3 Plaid would likely adopt the carbon-sleeved motors that the Model S Plaid had. However, packaging would be a major challenge, as Moravy said on the podcast, it would be a “tight engineering squeeze.”

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It’s important to note that there are no active production plans for the Model 3 Plaid at this point, but it’s also worth noting that with the Model S and Model X Plaid no longer available, Tesla would likely be willing to introduce something that is even more white-knuckle than the Model 3 Performance, which already boasts a 2.9-second 0-60 MPH acceleration rate and a top speed of 163 MPH.

Of course, there is the Roadster, but we don’t know when that will exactly make it to market, and we know that, for sure, it will not be accessible to many.

Tesla unveils juicy new detail on the Roadster and hints at new unveil timeline

Tesla has prided itself in building some of the best cars out there, but they’re also interested in building cars that are simply fun to be in.

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A Plaid Model 3 could truly push the limits and could end up being one of the best cars Tesla will ever build, especially if it can shave off at least half of a second from its 0-60 MPH time and increase its top speed slightly.

More than anything, the real changes will be in the ride and aerodynamics. Tesla improving things like the suspension, handling, and downforce will be the true trademarks of its Plaid powertrain; putting it in the Model 3 could be a great move for the company and for customers interested in high-end performance.

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NASA’s first human outpost on the Moon starts now – SpaceX on deck

NASA named the rovers, landers, and vendors that will build America’s first Moon Base.

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NASA has laid out its most detailed Moon Base plan to date, describing a permanent outpost near the Moon’s south pole that the agency intends to build over the coming decade as a direct stepping stone to Mars. “The Moon Base will be America’s and humanity’s first outpost on another celestial world,” NASA Administrator Jared Isaacman said, adding that every mission crewed and uncrewed “will be a learning opportunity as we return to the lunar surface, build the infrastructure to stay, and master the skills required to live and operate in one of the most demanding and dangerous environments imaginable.”

The plan is structured in three phases involving both uncrewed and crewed missions to deliver equipment, vehicles, and infrastructure to the surface, with the first three moon base missions targeted to launch before the end of 2026.

Moon Base I, targeting fall 2026, will use Blue Origin’s Blue Moon Mark 1 lander to deliver scientific instruments to the Shackleton Connecting Ridge, the same region where Artemis astronauts will land. Moon Base II will send Astrobotic’s Griffin lander carrying more than 1,100 pounds of cargo including Astrolab’s FLIP rover to begin developing mobility systems on the surface. Moon Base III will carry the Lunar Vertex science mission on Intuitive Machines’ Nova-C Trinity lander to study lunar swirls near the south pole, with ESA and Korean science payloads aboard.

Elon Musk pivots SpaceX plans to Moon base before Mars

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On the rover side, NASA awarded Astrolab $219 million and Lunar Outpost $220 million to build the first phase of Lunar Terrain Vehicles, with both rovers targeted for deployment to the lunar surface by 2028. Astrolab’s crewed rover weighs roughly 2,000 pounds and can reach over 6 mph. Lunar Outpost’s Pegasus rover can operate autonomously or via remote control at over 9 mph. Blue Origin separately received $188 million with an option worth $280.4 million to deliver cargo landers for rover transport.

NASA also confirmed that MoonFall, a mission deploying four survey drones to scout Artemis landing sites, has selected Firefly Aerospace to build the transport spacecraft, with a 2028 launch target.

SpaceX sits at the center of that commercial layer. SpaceX holds the NASA Human Landing System contract for the Starship-derived lander that will put astronauts on the surface under Artemis IV, currently targeting 2028. Before that can happen, SpaceX must demonstrate in-orbit propellant transfer at scale, a process requiring multiple Starship tanker launches to fuel a single mission. Water ice at the lunar south pole is central to the base’s long-term viability, as it can be converted into drinking water, breathable oxygen, and rocket fuel, directly reducing dependence on Earth resupply. That resource loop becomes far more practical if Starship can land and be refueled on or near the Moon itself.

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Elon Musk has publicly stated that Starship V3, which recently completed its first flight, should be capable enough for initial Mars missions. The Moon Base plan announced Tuesday is the infrastructure layer that connects everything between those two ambitions, and SpaceX is the only American company currently contracted to build the rocket that gets humans to either destination.

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