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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.

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.

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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 Twitter

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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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Elon Musk drops a surprise update on Boring Company’s next big dig

Musk says Boring Company could shrink the Austin to San Antonio drive to just minutes.

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Elon Musk says The Boring Company is working on what he called “a simple, precursor Hyperloop” tunnel connecting Austin and San Antonio, targeting speeds above 200 mph and cutting a drive that can take up to two and a half hours down to a consistent under 30 minutes. Musk posted the idea on X Sunday, in a reply to a repost of an AI generated video imagining a science fiction future with human colonies on other worlds, which he shared with the line “This is the future we shall bring into being.”


The Boring Company’s own account picked up the idea in the same thread, adding a detail about how the trip would actually work: “Because Loop/Hyperloop is express (i.e. no intermediate stops), one could travel from an Austin parking lot to a favorite San Antonio restaurant in about 30 minutes. As long as they both have Loop stations.” That framing ties the proposed intercity link to the same station model the company already runs in Las Vegas, where riders enter the tunnel network through small, garage style stops rather than one central terminal.

This is not the company’s first run at the Austin to San Antonio corridor. Boring Company floated tunnels between the two cities as far back as 2021, and later competed for a separate San Antonio Loop project tied to the airport before that specific bid stalled. Pitches for tunnels in Chicago, Los Angeles, and a New York to Washington corridor have followed a similar pattern of big announcement without a shovel in the ground.

What is different this time is the balance sheet, especially since The Boring Company closed a 3 billion dollar funding round led by investors in the United Arab Emirates earlier this month at a valuation near 23 billion dollars, giving the tunneling company more capital to chase speculative projects than it had during its earlier Texas pitches. The company is also mid-build on two other intercity systems it has actually broken ground on, inc;luding a Nashville tunnel linking downtown to the airport, where a second boring machine finished commissioning in June, and its Las Vegas network, where the station count keeps climbing on paper faster than tunnels get dug.

That gap between announcement and execution is the reason to treat Sunday’s post as an opening bid rather than a project. A tunnel spanning roughly 80 miles between two metro areas, running at speeds Boring Company has not demonstrated over any real distance, would dwarf anything the company has built. For now, the Austin to San Antonio Hyperloop exists as a caption under an AI generated space video.

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Tesla eyes supply partners for Optimus mass production

Tesla certified three Chinese suppliers for Optimus mass production, signaling its robot timeline is accelerating.

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Concept rendering of Tesla Optimus in mass production

Tesla’s robotics team traveled to Ningbo, in China’s Zhejiang province, on September 16 and spent the following day auditing component suppliers for Optimus, according to a Bloomberg report cited by RobotAIGeek. The visit moved three manufacturers from provisional status to certified mass production partners: Tuopu Group, which handles actuators and chassis components, Ningbo Joyson Electronic, a sensor supplier, and Zhejiang Sanhua Intelligent Controls, which builds thermal management systems. All three already supply parts to Tesla’s electric vehicles, and the audit reportedly came with fresh orders that supply chain reports put at an initial batch of roughly 5,000 units.

Tuopu, Joyson, and Sanhua built their manufacturing base serving the automotive industry, where tolerances and volume requirements are already close to what a mass produced humanoid robot demands. Sanhua in particular has history here. Teslarati reported last October that the company had received a roughly $685 million order for linear actuators tied to Optimus, a volume industry watchers estimated could cover around 180,000 robots once production ramped.

Supply chain reports tied to this week’s audit put Tesla’s near term production goal at about 1,000 Optimus units a week by late September, rising to 2,000 to 2,500 units a week by the end of the year. That pace would put real weight behind the timeline Tesla has been building toward since May, when it wound down Model S and Model X production at Fremont to convert that floor space into a dedicated Optimus line targeting one million units annually. JPMorgan analysts who toured the factory in August confirmed the conversion took roughly four months, a pace Musk has called unprecedented for a facility that size.

New drone video shows Tesla’s Optimus Factory reaching a turning point

Fremont is only the first phase. A second, larger Optimus plant is rising at Gigafactory Texas, where drone footage shared by Joe Tegtmeyer last week showed the structural steel nearing completion on the north end of the building. Tesla has said that facility is meant to eventually support production of up to 10 million units a year, though volume output there is not expected before 2027.

Commercial sales of Optimus are still targeted for the second half of 2027, but production is expected to start well before then. JPMorgan analyst Rajat Gupta has said Tesla’s “Optimus Academy” program, which uses early units to collect real world training data inside Tesla’s own facilities, is expected to be running later this year. Bloomberg Intelligence analyst Ian Ma described the Ningbo audits as “a positive commercialization signal for China’s humanoid supply chain,” noting that sentiment could improve further if the visit leads to confirmed supplier nominations and larger orders. The Solactive China Humanoid Robotics Index rose about 1.4% on the news, though it remains down roughly 30% for the year.

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Elon Musk’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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