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SpaceX’s Falcon 9 wins launch of an asteroid-attacking NASA spacecraft

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Just minutes before SpaceX began fueling Falcon Heavy for its commercial launch debut, NASA announced that the company had won a contract for its Double Asteroid Redirection Test (DART) mission, to be launched by Falcon 9 for the low cost of $69M.

Designed to cost less than $250M total, the DART mission will aim to be as light and fast as possible, using a dedicated Falcon 9 to send the ~600 kg (~1300 lb) spacecraft and its Italian companion cubesat on an ~11 million kilometer (~7M mi) journey to the binary asteroid Didymos. The ultimate purpose of DART is to effectively prove out both technologies and physics that could be used in the future to defend Earth from asteroids known to be on a collision course.

If all goes as planned during DART’s imminent design review milestones and hardware integration, Falcon 9 could launch the spacecraft towards the Didymos asteroid system in June 2021 for an October 2022 arrival. That “arrival” would involve DART impacting Didymos-B – the smaller of the pair at 163 m (535 ft) across – at a relative velocity of more than 6 km/s (3.7 mi/s). Nicknamed Didymoon, Didymos-B effectively orbits Didymos-A. At that speed, the ~600 kg probe will create an impact with the equivalent explosive force of nearly two and a half tons of TNT, the purpose of which is to determine just how much the sheer kinetic energy of impact can modify a small body’s orbit around the main asteroid.

Estimates from the spacecraft’s mission managers expect Didymoon’s orbit to be shifted by about 1% as measured by the time it takes to orbit Didymos-A, from ~11.9 hours to ~11.8 to 12.0 hours. This is a very small change but one that should – in theory – be easily measurable by telescopes on Earth, despite the fact that Didymoon has been estimated to have a mass of approximately 3.5 million metric tons (7.6 billion pounds), approximately seven million times heavier than DART. In short, NASA is going to functionally bomb an asteroid moon to see if humans might be able to use kinetic impactors to gently ‘boop’ threatening space objects off of the offending trajectory years or even decades in advance.

Despite the inherently destructive, single-use nature that DART’s impactor status bestows, current plans thankfully include an Italian cubesat known as LICIACube. The small copassenger will deploy two days before impact to fully exploit the scientific value of DART’s demise with high-quality photos of the event and aftermath. LICIACube will be traveling the same speed and thus won’t be able to enter orbit around the asteroid system, but a European Space Agency (ESA) mission known as Hera plans to do just that in the mid-2020s to better characterize Didymos and the crater (hopefully) made by DART.

Aside from the mission itself, DART serves as a technology demonstration platform for NASA. It will mark the first in-space use of the NASA-built NEXT-C ion thruster and powerpack, as well as the first standalone use of Roll-Out Solar Array (ROSA) deployment mechanism (shown above being tested on the ISS). Even more intriguing is a proposed transformational solar array planned at one point for DART, a flexible combination of advanced solar cells (~33% efficient) and mirror concentrators that could feed a spacecraft five times as much power for a given solar array area and distance from the sun. It’s unclear whether this will make it into DART’s final design but it still appears to be on the table as of January 2019. According to the contracted manufacturer, DART’s solar array will produce ~6.6 kW, while rough estimates suggest that the solar array will have an area of 16 m^2 (170 ft^2). Relative to the simplicity of the deployment mechanism and small size of DART (~600 kg total), this is an incredible amount of accessible power.

The most recent render of the NASA/APL DART spacecraft. (NASA/APL)
Falcon 9 B1045 rolls out to LC-40 ahead of SpaceX’s first dedicated NASA payload, the TESS exoplanet observatory. (SpaceX)

Getting to orbit

For NASA’s SpaceX launch contract, the agency will pay just $69M, barely 10% above Falcon 9’s bare-minimum list price of $62M. It’s safe to assume that the timing of the contract award – days after SpaceX abruptly dropped an official protest of ULA winning a ~$150M NASA contract – might not be coincidence. Regardless, SpaceX’s decision to bid so low for a NASA launch does lend some serious credence to the company’s protest that ULA’s contract for the mission – NASA’s LUCY asteroid explorer – was “vastly more [expensive]” than the bid SpaceX submitted.

Weighing just ~600 kg (~1300 lb) wet, DART could end up launching with additional copassengers on Falcon 9, although there is a precedent set by NASA’s ~360 kg TESS and Taiwan’s Formosat-5 for SpaceX giving tiny spacecraft dedicated launches. Additionally, it’s possible that DART will launch on a flight-proven Falcon 9 Block 5 rocket, given the likelihood that NASA will have certified flight-proven SpaceX vehicles for almost any launch by 2021.

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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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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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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.

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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.

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.

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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.

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SpaceX Terafab rendering

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.

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