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SpaceX attempts second Falcon fairing drop test with a helicopter and Mr. Steven
Following a few days of rest in port, SpaceX fairing recovery vessel Mr. Steven has continued a likely campaign of controlled drop tests with a second fairing recovery attempt, using a helicopter, spotter plane, and support vessel to pick up a Falcon fairing and drop it, theoretically allowing it to paraglide into Mr. Steven’s net.
While it’s nearly impossible to determine what happened without line-of-sight visual confirmation or an official announcement from SpaceX, it appears that Mr. Steven kicked off real catch attempts on October 11th, evidenced by his close interaction with a Blackhawk helicopter over the course of an hour or so. Another similar attempt occurred today, October 17th, and culminated with Mr. Steven returning once more to Port of San Pedro with the same test-focused fairing half on board, albeit not resting in his retracted net.
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- SpaceX’s dedicated test fairing seen at Berth 240 on Oct. 15, a few days after its first apparent drop test. (Pauline Acalin)
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- Mr. Steven and a recent arrival, barge PTS 185. The fairing cradle on deck suggests that this is probably the platform helicopters grab the fairing half off of. (Pauline Acalin)
After October 11th’s testing was completed, Mr. Steven returned to Port of San Pedro. On October 13th, he was docked at SpaceX’s Berth 240 facilities with net lowered and the test fairing half wrapped up on the docks, preventing confirmation of whether he carried the fairing half back from the testing region. A mid-sized barge also recently appeared at Berth 240 with a distinct Falcon fairing cradle onboard, perhaps explaining the presence of a tugboat (named Sir Richard) a few miles away from where this test campaign has been stationed – a barge would offer a flat, safe surface for a helicopter to hover over and pick up an unwieldy object such as a payload fairing.
Nearly identical to the October 11th test, Mr. Steven, tug Sir Richard, a Cessna chase plane, and a Blackhawk helicopter all converged around 100 miles southwest of Port of Los Angeles around 2pm PDT on October 17th prior to beginning recovery test operations. Mr. Steven and the tug Sir Richard – likely towing a barge being temporarily used to move a fairing half – arrived several hours beforehand at the test’s planned location.
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- As of late, SpaceX technicians and engineers have going through quite a range of activities related to fairing recovery. (Pauline Acalin)
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- A gif demonstrates just how taut Mr Steven’s net can be, thanks to mechanized rigging. 08/13/18 (Pauline Acalin)
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- Mr. Steven returned to Port of San Pedro around 7pm on October 8th after a day spent at sea, apparently with a Falcon fairing half in tow. This is the second known time that a fairing has been in Mr. Steven’s net. (Pauline Acalin)
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- One half of SpaceX’s Iridium-6/GRACE-FO just moments before touchdown on the Pacific Ocean. (SpaceX)
Eventually, a UH-60A Blackhawk helicopter – the same helicopter used on October 11 – lifted off from Catalina Island’s Avalon airport, taking about half an hour to reach Mr. Steven and Sir Richard. Once there, the helicopter very distinctly slowed down, eventually hovering just ~20 feet off the surface of the ocean, if not outright landing or perching on the aforementioned barge under the tug’s control. After several minutes in that state, the Blackhawk lifted off and immediately began climbing, reaching a peak of ~11,000 ft before (presumably) dropping its fairing payload and immediately diving down to follow its descent.
It’s undoubtedly an imperfect fit, but the helicopter appeared to follow Mr. Steven very closely over the course of the recovery attempt, sticking just a ~1500 ft or less above and a few hundred feet beside him as he raced to catch the falling fairing half. In fact, at least as a very rough approximation, the helicopter’s descent may be useful to judge the fairing’s behavior while gliding: taking ~14 minutes to travel descend 11,000ft and travel perhaps 2 miles (~10,500ft) horizontally, the fairing would dropped at a reasonable 13.1 feet per second (~4 m/s) once its parafoil opened and seemed to travel approximately one foot forward for every one foot down, also known as a 1:1 glide slope ratio.
And here's a little overview of the helicopter's path, mixed with a speed/altitude graph! Added some rough annotations to give an idea of what happened and in what time frame 😀 pic.twitter.com/e1rwZtkNHA
— Eric Ralph (@13ericralph31) October 18, 2018
Depending on wind conditions, parafoils can nominally be expected to achieve average glide slope ratios between 0 (high winds; falling like a literal rock) and 4 (no winds; almost as good as a bad airplane), meaning that Falcon fairings – judging from tangential data gathered from the helicopter following its descent – fly much like a parafoil, which is to say not great but better than a brick. The trick with parafoil control – which includes tweaking angles of attack and glide slope – lies more in the art of trading forward velocity for vertical velocity (or vice versa) at key moments. Assuming their control mechanisms have enough authority, paragliding fairings could ‘flare’ as they near Mr. Steven’s net, essentially angling upwards to briefly hover before dropping quickly, maybe giving the boat enough time to swoop in and place its net just beneath it.
In this way, a parafoil’s flexible, inflated wing (airfoil, to be precise) can allow it to maneuver quite a lot like a bird, at least more so than most other methods of flying humans have access to. Time will tell if SpaceX is having any luck perfecting the guidance and recovery of Falcon fairings, particularly with this campaign of under-the-radar drop tests. Even if Mr. Steven returns with a fairing half resting in his net, it will be more than a little ambiguous if it was placed there or he caught it, and any certainty will rely on official confirmation from SpaceX itself.
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News
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years.
The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Dry cathode 4680 cells
In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.
The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”
Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.
4680 packs for Model Y
Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla:
“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”
The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.
Elon Musk
Tesla Giga Texas to feature massive Optimus V4 production line
This suggests that while the first Optimus line will be set up in the Fremont Factory, the real ramp of Optimus’ production will happen in Giga Texas.
Tesla will build Optimus 4 in Giga Texas, and its production line will be massive. This was, at least, as per recent comments by CEO Elon Musk on social media platform X.
Optimus 4 production
In response to a post on X which expressed surprise that Optimus will be produced in California, Musk stated that “Optimus 4 will be built in Texas at much higher volume.” This suggests that while the first Optimus line will be set up in the Fremont Factory, and while the line itself will be capable of producing 1 million humanoid robots per year, the real ramp of Optimus’ production will happen in Giga Texas.
This was not the first time that Elon Musk shared his plans for Optimus’ production at Gigafactory Texas. During the 2025 Annual Shareholder Meeting, he stated that Giga Texas’ Optimus line will produce 10 million units of the humanoid robot per year. He did not, however, state at the time that Giga Texas would produce Optimus V4.
“So we’re going to launch on the fastest production ramp of any product of any large complex manufactured product ever, starting with building a one-million-unit production line in Fremont. And that’s Line one. And then a ten million unit per year production line here,” Musk stated.
How big Optimus could become
During Tesla’s Q4 and FY 2025 earnings call, Musk offered additional context on the potential of Optimus. While he stated that the ramp of Optimus’ production will be deliberate at first, the humanoid robot itself will have the potential to change the world.
“Optimus really will be a general-purpose robot that can learn by observing human behavior. You can demonstrate a task or verbally describe a task or show it a task. Even show it a video, it will be able to do that task. It’s going to be a very capable robot. I think long-term Optimus will have a very significant impact on the US GDP.
“It will actually move the needle on US GDP significantly. In conclusion, there are still many who doubt our ambitions for creating amazing abundance. We are confident it can be done, and we are making the right moves technologically to ensure that it does. Tesla, Inc. has never been a company to shy away from solving the hardest problems,” Musk stated.
Elon Musk
Rumored SpaceX-xAI merger gets apparent confirmation from Elon Musk
The comment follows reports that the rocket maker is weighing a transaction that could further consolidate Musk’s space and AI ventures.
Elon Musk appeared to confirm reports that SpaceX is exploring a potential merger with artificial intelligence startup xAI by responding positively to a post about the reported transaction on X.
Musk’s comment follows reports that the rocket maker is weighing a transaction that could further consolidate his space and AI ventures.
SpaceX xAI merger
As per a recent Reuters report, SpaceX has held discussions about merging with xAI, with the proposed structure potentially involving an exchange of xAI shares for SpaceX stock. The value, structure, and timing of any deal have not been finalized, and no agreement has been signed.
Musk appeared to acknowledge the report in a brief reply on X, responding “Yeah” to a post that described SpaceX as a future “Dyson Swarm company.” The comment references a Dyson Swarm, a sci-fi megastructure concept that consists of a massive network of satellites or structures that orbit a celestial body to harness its energy.
Reuters noted that two entities were formed in Nevada on January 21 to facilitate a potential transaction for the possible SpaceX-xAI merger. The discussions remain ongoing, and a transaction is not yet guaranteed, however.
AI and space infrastructure
A potential merger with xAI would align with Musk’s stated strategy of integrating artificial intelligence development with space-based systems. Musk has previously said that space-based infrastructure could support large-scale computing by leveraging continuous solar energy, an approach he has framed as economically scalable over time.
xAI already has operational ties to Musk’s other companies. The startup develops Grok, a large language model that holds a U.S. Department of Defense contract valued at up to $200 million. AI also plays a central role in SpaceX’s Starlink and Starshield satellite programs, which rely on automation and machine learning for network management and national security applications.
Musk has previously consolidated his businesses through share-based transactions, including Tesla’s acquisition of SolarCity in 2016 and xAI’s acquisition of X last year. Bloomberg has also claimed that Musk is considering a merger between SpaceX and Tesla in the future.
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
Tesla Giga Texas to feature massive Optimus V4 production line
