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SpaceX rings in the New Year with preparations for first Falcon 9 launch of 2020

Cruise ship passenger Max Kalika caught this photo of drone ship Of Course I Still Love You (OCISLY) heading to sea for SpaceX's first launch and landing of the new year. (Max Kalika)

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SpaceX’s first Falcon 9 launch of 2020 – and the new decade – is just around the corner after drone ship Of Course I Still Love You (OCISLY) departed Port Canaveral on Monday to prepare for its 27th booster landing attempt.

Known as Starlink-2, SpaceX’s first launch of the new year slipped a handful of days from December 30th to January 3rd and finally January 6th and will be the company’s second launch of 60 upgraded Starlink v1.0 satellites, as well as the third dedicated Starlink launch overall. Just one of potentially dozens of SpaceX launches planned in 2020, the year is setting up to be – by a long shot – the company’s most ambitious year ever.

Meanwhile, Starlink-2 alone is set to ring in at least two significant milestones, pushing the nascent broadband internet constellation a step closer to serving customers and Falcon 9 reusability a step closer to being fully realized.

Drone ship OCISLY departed Port Canaveral on December 30th and is now being towed some 630 km (390 mi) downrange to Falcon 9’s planned Atlantic Ocean recovery location. SpaceX’s first launch and landing of 2020 will also be the three-year-old drone ship’s 27th attempted Falcon booster recovery and – hopefully – 23rd successful recovery.

Simultaneously, SpaceX technicians are in the midst of preparing other recovery fleet assets for what appears to be a partial fairing recovery attempt. Twin fairing catchers Ms. Tree and Ms. Chief debuted on their first simultaneous fairing catch attempt in December 2019 but each unfortunately missed their catches, instead picking up the floating fairing halves off the surface of the Atlantic and returning to port on December 18th.

The fairing halves were thus still successfully recovered and may be able to fly again on a future Starlink mission, but both fairing recovery ships suffered damage during their first simultaneous deployment. Ms. Tree suffered minimal damage in the form of tears to its secondary net – an easy fix – but Ms. Chief was not as lucky and somehow lost one of the two white booms that support each of her four arms.

That wounded arm was visibly hanging lower than its companions when Ms. Chief returned to port and technicians have since removed all of her arms, presumably evaluating whether the ordeal overstressed any components or caused significant damage.

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Unsurprisingly, Ms. Chief will reportedly not take part in the fairing recovery portion of SpaceX’s imminent Starlink-2 launch, although it’s starting to look like Ms. Tree will be able to attempt a catch. SpaceX will still attempt to extract both fairing halves from the Atlantic even if the catch attempt fails and appears to be preparing GO Navigator to recover the half that would have otherwise been assigned to Ms. Chief.

Two milestones, one launch

As implied by the Starlink-2 title, SpaceX’s first launch of 2020 will feature the third batch of 60 Starlink satellites. Excluding 9 Starlink v0.9 satellites that have been intentionally lowering their orbits over the last several months to hasten reentry, this will give SpaceX a constellation of at least 170 operational satellites less than eight months after the company began launching the satellites.

The first 60 Starlink v1.0 satellites deployed in one giant, 16-18 metric-ton blob on November 11th. (SpaceX)

This may not immediately seem significant but 170 operational satellites in orbit could make Starlink the world’s largest satellite constellation and SpaceX the world’s largest constellation operator. The only known competitor that comes close is Planet Labs, an Earth observation company believed to have approximately 150-170 operational satellites in orbit – most of which are 5-10 kg (10-20 lb) ‘Doves’ roughly the size of a loaf of bread.

Put another way, after Starlink-2, SpaceX will have around 45 metric tons (100,000 lb) of functional Starlink satellites in orbit, a constellation mass probably only rivaled by major geostationary commsat operators, global navigation satellites, and a few other high-value military constellations.

Meanwhile, according to NASASpaceflight.com, SpaceX has assigned Falcon 9 booster B1049.3 to its Starlink-2 mission, meaning that the launch will mark the second time that a single SpaceX rocket has flown four orbital-class missions. This follows on the footsteps of the November 11th, 2019 Starlink-1 launch, which saw Falcon 9 B1048 become the first booster to fly four times.

At this point, SpaceX has two additional Starlink launches scheduled in January and has plans for as many as 38 orbital launches throughout 2020. To complete that incredibly ambitious manifest, SpaceX will have to dig deep into its fleet of reusable rockets, meaning that Falcon 9 B1049’s imminent fourth launch is almost certainly just the tip of the iceberg. Falcon 9 B1049 is scheduled to launch SpaceX’s Starlink-2 mission no earlier than (NET) 9:20 pm ET, January 6th (02:20 UTC, Jan 7).

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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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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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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.

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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.

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