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SpaceX eyes major drone ship fleet upgrades and a new rocket recovery robot

SpaceX's 'Octagrabber' rocket recovery robot is pictured on drone ship OCISLY's deck in February 2019. (Pauline Acalin)

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SpaceX has kicked off a series of major upgrades planned for its East Coast fleet of drone ships, centered around Just Read The Instructions (JRTI) and most recently culminating in the apparent fabrication of a second tank-like rocket recovery robot.

Back in Q4 2019, West Coast drone ship JRTI officially departed the Port of Los Angeles berth it operated out of for 3+ years — traversing the Panama Canal, making a weeks-long pit-stop in a Louisiana port, and ultimately arriving at Port Canaveral on December 11th. The modified barge spent more than a month relatively untouched – as was the somewhat mysterious cargo it had brought with it from the Gulf Coast – before SpaceX began JRTI’s long-awaited upgrades around a month ago.

For almost half a year, it’s looked like that SpaceX would move its West Coast drone ship to Florida after the company’s Vandenberg Air Force Base (VAFB) pad entered a major lull in launch activities in early 2019. Aside from one launch in June 2019, SpaceX’s West Coast pad has remained unused and that isn’t expected to change anytime soon. With Cape Canaveral potential reopening its dormant polar launch corridor just weeks from now, it’s entirely possible that SpaceX will be able to perform all of its planned launches from Florida alone for at least the next 6-12 months. Targeting more than 30 East Coast launches in 2020 alone, SpaceX could also benefit from at least one additional drone ship to continue high-volume Falcon booster recoveries without ship availability becoming a major launch constraint. Thankfully, JRTI may be the perfect solution.

Informally known as ‘Octagrabber’, a reference to the robot’s primary function, SpaceX has been using the only operational instance of the vehicle on drone ship Of Course I Still Love You (OCISLY) for more than two years, beginning in 2017. While far from autonomous, Octagrabber helps SpaceX’s maritime rocket recovery team minimize the risks workers are subjected to and gives the company a bit more flexibility to attempt Falcon booster landings in less-than-pristine ocean weather.

While Falcon boosters are relatively stable once landed, thanks to the vast majority of their empty mass being concentrated around their nine Merlin 1D engines, even moderate waves can cause them to slip and slide around the drone ship deck.

Falcon Heavy center core B1055 successfully landed aboard drone ship OCISLY nearly 970 km (600 mi) off the coast of Florida but was lost soon after when it tipped over in high seas. (SpaceX)
Octagrabber robots are meant to prevent boosters from sliding off of drone ship decks by anchoring them with their tank-like weight. (Teslarati)

In fact, the best operational demonstration of the value of Octagrabber-style recovery robots came after SpaceX’s historic Falcon Heavy triple-booster recovery in April 2019 – the first time all three of the rocket’s first stage boosters successfully landed after liftoff. As it turns out, thanks to moderate hardware differences between Falcon Heavy center core boosters and normal Falcon 9 boosters, OCISLY’s Octagrabber robot did not have the attachment mechanisms needed to ‘grab’ the center core (B1055, in this case). In theory, this could be a non-issue but the drone ship unfortunately ran into high seas, making its deck to pitch and tilt and ultimately causing to B1055 to tip over, breaking in half and effectively destroyed the booster.

With Octagrabber robots, drone ships should almost never lose recovered boosters because of high seas (within reason). As such, it should come as no surprise at all that SpaceX is building a new recovery robot for drone ship JRTI – the newest addition to its Florida fleet.

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Falcon 9 B1048 returns to Port of LA aboard drone ship JRTI after completing its launch debut in August 2018. (Pauline Acalin)

Aside from the discovery of a second Octagrabber being built at SpaceX’s former East Coast Starship factory, the nature of other upgrades planned for drone ship JRTI are more mysterious. For several months, the rocket landing platform has had almost a dozen massive generators and new thruster pods stored on its deck, seemingly waiting on an unknown impetus for their installation. In recent weeks, visible work to prepare the new hardware for installation has begun.

Notably, the thrusters and power supplies that seem destined for installation on JRTI would make for a dramatic upgrade, potentially giving the drone ship more power than the tug boats that must currently tender and tow them to landing zones. In other words, that’s a complicated way of saying that SpaceX may be trying to make drone ship JRTI almost entirely independent of contracted tugboats, potentially simplifying and lowering the cost of booster recoveries.

One day soon, SpaceX’s upgraded drone ships may be able to recover boosters and return them to shore without any human technicians. (Richard Angle)

While less likely, it’s also possible that SpaceX is finally in a position to fully realize the “autonomous” namesake of its autonomous spaceport drone ships (ASDS), with high-powered thrusters potentially giving JRTI the ability to leave port, cruise to Atlantic Ocean landing zones, deploy an Octagrabber, and return to port with a booster – all without humans in the loop. That capability is likely still on the horizon but powerful thrusters and generators would bring port-to-port drone ship autonomy within SpaceX’s grasp in the near future.

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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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