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SpaceX’s upcoming Starlink launch will set a record for Falcon 9 booster reuse

Falcon 9 B1021 became the first orbital-class booster to launch and land twice in March 2017. (SpaceX)

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SpaceX’s next launch will fly on a Falcon 9 Block 5 booster with three flights in its history, making the mission the first time SpaceX will launch the same orbital-class booster four times.

Likely attributable to a number of launch customers all coincidentally not ready for flight, SpaceX is in the midst its longest lull between launches since September 2016, three years ago, when Falcon 9 suffered its most recent catastrophic failure. During the lull, SpaceX COO and President Gwynne Shotwell noted that this is the first time in SpaceX’s history where the company is waiting on customers to launch, rather than the other way around.

That lull – currently past the two-month marker – is hoped to end sooner than later, although SpaceX’s ‘return-to-flight’ mission has become more uncertain in the last few weeks. For unknown reasons, the schedule for SpaceX’s next Starlink mission(s) went from having fairly specific launch targets (October 17th and November 4th) to more unclear schedules. Currently, SpaceX’s next launch will likely be the first flight of 60 Starlink V1.0 satellites and is expected no earlier than late-October or November.

An imposing stack of SpaceX’s first 60 Starlink satellites is shown here prior to their inaugural launch. (SpaceX)

Depending on how far right the mission moves on that schedule, SpaceX’s next launch might instead be a more regular commercial satellite mission, Kacific 1, scheduled for launch no earlier than (NET) November 11th.

Regardless of which mission actually comes next, speaking earlier this at the 2019 National Academy of Engineering annual meeting, SpaceX VP of Build and Flight Reliability revealed that “the next launch” will mark the first time a Falcon 9 booster has launched four times. As of now, SpaceX has launched four separate Falcon 9 boosters three times apiece, beginning with B1046 in December 2018 and ending most recently with B1047 in August 2019.

Three of SpaceX’s flight-proven Falcon 9 boosters are pictured here: B1046, B1048, and B1049. (Tom Cross & Pauline Acalin)

According to CEO Elon Musk and other SpaceX executives and employees, Falcon 9 Block 5 boosters are designed to fly no fewer than 10 times apiece before requiring substantial refurbishment. SpaceX has three (B1047 was expended on its third flight) thrice-flown Falcon 9 Block 5 boosters on hand, all of which can thus be assumed to be ready for another mission. In fact, B1046.3 is known to be assigned to SpaceX’s imminent Crew Dragon In-Flight Abort (IFA) test (NET November 23rd).

This leaves B1048 and B1049 as SpaceX’s booster options for their next launch. Assuming it’s a Starlink, it seems likely that B1049 would be the booster of choice, as that particular booster supported SpaceX’s first Starlink v0.9 launch back in May 2019. On the other hand, Falcon 9 B1048 completed its third launch in February 2019, meaning that it has had more time for post-flight inspections and (minimal) refurbishment, although it’s entirely unclear what sort of timescales SpaceX is currently operating on for Block 5 booster reuse.

Regardless of the specifics, SpaceX’s plans for a prolific number of internal Starlink launches will create a huge number of opportunities for the company to test new hardware/software and push the envelope of reusability, all without having to convince paying customers to be the guinea pigs. Once SpaceX has pushed its booster fleet onto their fourth flights, Starlink missions can easily take the reins and prove the safety of five-flight Falcon 9s and beyond.

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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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Tesla eyes supply partners for Optimus mass production

Tesla certified three Chinese suppliers for Optimus mass production, signaling its robot timeline is accelerating.

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Concept rendering of Tesla Optimus in mass production

Tesla’s robotics team traveled to Ningbo, in China’s Zhejiang province, on September 16 and spent the following day auditing component suppliers for Optimus, according to a Bloomberg report cited by RobotAIGeek. The visit moved three manufacturers from provisional status to certified mass production partners: Tuopu Group, which handles actuators and chassis components, Ningbo Joyson Electronic, a sensor supplier, and Zhejiang Sanhua Intelligent Controls, which builds thermal management systems. All three already supply parts to Tesla’s electric vehicles, and the audit reportedly came with fresh orders that supply chain reports put at an initial batch of roughly 5,000 units.

Tuopu, Joyson, and Sanhua built their manufacturing base serving the automotive industry, where tolerances and volume requirements are already close to what a mass produced humanoid robot demands. Sanhua in particular has history here. Teslarati reported last October that the company had received a roughly $685 million order for linear actuators tied to Optimus, a volume industry watchers estimated could cover around 180,000 robots once production ramped.

Supply chain reports tied to this week’s audit put Tesla’s near term production goal at about 1,000 Optimus units a week by late September, rising to 2,000 to 2,500 units a week by the end of the year. That pace would put real weight behind the timeline Tesla has been building toward since May, when it wound down Model S and Model X production at Fremont to convert that floor space into a dedicated Optimus line targeting one million units annually. JPMorgan analysts who toured the factory in August confirmed the conversion took roughly four months, a pace Musk has called unprecedented for a facility that size.

New drone video shows Tesla’s Optimus Factory reaching a turning point

Fremont is only the first phase. A second, larger Optimus plant is rising at Gigafactory Texas, where drone footage shared by Joe Tegtmeyer last week showed the structural steel nearing completion on the north end of the building. Tesla has said that facility is meant to eventually support production of up to 10 million units a year, though volume output there is not expected before 2027.

Commercial sales of Optimus are still targeted for the second half of 2027, but production is expected to start well before then. JPMorgan analyst Rajat Gupta has said Tesla’s “Optimus Academy” program, which uses early units to collect real world training data inside Tesla’s own facilities, is expected to be running later this year. Bloomberg Intelligence analyst Ian Ma described the Ningbo audits as “a positive commercialization signal for China’s humanoid supply chain,” noting that sentiment could improve further if the visit leads to confirmed supplier nominations and larger orders. The Solactive China Humanoid Robotics Index rose about 1.4% on the news, though it remains down roughly 30% for the year.

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Elon Musk’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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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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