News
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.
- SpaceX’s dedicated test fairing seen at Berth 240 on Oct. 15, a few days after its first apparent drop test. (Pauline Acalin)
- 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.
- As of late, SpaceX technicians and engineers have going through quite a range of activities related to fairing recovery. (Pauline Acalin)
- A gif demonstrates just how taut Mr Steven’s net can be, thanks to mechanized rigging. 08/13/18 (Pauline Acalin)
- 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)
- 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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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.
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.
The Giga Texas Optimus Factory latest update … construction keeps moving fast!
Steel assembly is now only about 5 column grids from the north perimeter beam. Concrete is going in on the three upper floors, rebar is still being laid for more pours, and footing / grade-beam work… pic.twitter.com/qvFPvwnYzW
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) September 17, 2026
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.
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.
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.
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.
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.
News
NHTSA just escalated its Tesla Cybercab investigation in a big way
NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.
Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.
The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.
Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.
The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.
Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.





