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SpaceX’s next Falcon Heavy launch may feature record-breaking center core landing

Falcon Heavy clears the top of the tower in a spectacular fashion during its debut launch. (Tom Cross/Pauline Acalin)

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Thanks to a temporary reopening of the US federal government, SpaceX was finally able to continue the process of filing FCC and FAA paperwork needed to acquire permits for upcoming launches, including Falcon Heavy.

One such filing related to the first operational Falcon Heavy launch has revealed a fairly impressive statistic: comprised of three first stage boosters, SpaceX indicated that Falcon Heavy’s center core will attempt to land on drone ship Of Course I Still Love You (OCISLY) nearly 1000 km (600 mi) away from its launch site, easily smashing the record for the greatest distance traveled by a Falcon booster in flight.

The same FCC filings also revealed a No Earlier Than (NET) launch date: March 7, 2019. Originally targeted for mid to late February, the complexity and logistical challenges of building, shipping, testing, and delivering two side boosters, a center core, one upper stage, and a payload fairing from SpaceX’s California factory to its Texas test facilities and Florida launch pad unsurprisingly took a small toll on the launch’s aspirational schedule. Nevertheless, if the launch data actually holds to March 7th, SpaceX will not have missed the mark by much considering that this Falcon Heavy – based on new and more powerful Block 5 boosters – is likely a significant departure from the Block 2/Block 3 hardware that has flight heritage from the triple-booster rocket’s Feb. 2018 launch debut.

The second (and third) flight of Falcon Heavy is even closer to reality as a new side booster heads to Florida after finishing static fire tests in Texas. (Reddit /u/e32revelry)

Just shy of a year after Falcon Heavy’s launch debut, it appears that the rocket’s second and third launches were pushed back by a fundamental lack of production capacity. In other words, SpaceX’s Hawthorne rocket factory simply had to focus on more critical priorities in the 6-9 months that followed the demo mission. At nearly the same time as Falcon Heavy was lifting off for the first time, SpaceX’s world-class production crew was in the midst of manufacturing the first upgraded Falcon 9 Block 5 booster (B1046) and wrapped up final checkouts just 10 days after Heavy’s Feb. 6 launch debut, sending the pathfinder rocket to McGregor, Texas for the first static fire of a Block 5 booster.

In the meantime, SpaceX’s decision to intentionally expend otherwise recoverable reused Falcon boosters after their second launches meant that the company’s fleet of flightworthy rockets was rapidly approaching zero, a move CEO Elon Musk specifically indicated was meant to make room for Block 5, the future (and final form) of the Falcon family. SpaceX’s busy 2018 launch manifest and multiple critical missions for the US government were thus balanced on the success, reliability, and rapid production of a serious number of Merlin engines, boosters, and upper stages. This included B1051 – the first explicitly crew-rated Falcon 9 – and B1054, the first SpaceX rocket rated to launch high-value US military (specifically Air Force) satellites. However, SpaceX also needed to produce a cadre of Falcon 9 boosters capable of easy reuse to support the dozen or so other commercial launches on the manifest.

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That gamble ultimately paid off, with Block 5 performing admirably and supporting a reasonable – if not record-breaking – rate of reuse. SpaceX successfully launched B1054 for the USAF, completed B1051 (now at Pad 39A awaiting NASA’s go-ahead), and built enough reusable Block 5 boosters to support nine additional commercial missions in 2018. In hindsight, barring an assumption of a truly miraculous and unprecedented Falcon booster production rate, Falcon Heavy’s next launches were almost guaranteed to occur no fewer than 6-12 months after the rocket’s launch debut – SpaceX’s entire launch business depended on building 5+ unrelated Falcon 9 boosters, while Falcon Heavy customers Arabsat and the USAF were unlikely to be swayed to launch on flight-proven hardware so early into Block 5’s career.

https://twitter.com/_TomCross_/status/1048483536917823488

All cylinders firing

Once Falcon 9 B1054 departed SpaceX’s Hawthorne factory (see above) in early October, it appears that the company’s production team pivoted directly to integrating and shipping the next three (or more) Falcon Heavy boosters back to back for the rocket’s second and third launches. The first new side booster departed the factory in mid-November, followed by a second side booster in early December and a (presumed but highly likely) center core at the turn of 2019. Both side boosters have been static-fired in Texas and are now at SpaceX’s Florida facilities, while the center core either just completed its Texas static fire testing or is already on its way East.

 

Once the center core and upper stage make their way to SpaceX’s Kennedy Space Center Pad 39A, the company’s technicians and engineers will be able to integrate the second Falcon Heavy to have ever existed in preparation for a critical static fire test. That could occur as early as February, although the launch debut of Crew Dragon (DM-1) – now NET March from Pad 39A after a relentless string of slips – will likely take precedence over Falcon Heavy and could thus directly interfere with its launch, as the launch pad and transporter/erector (T/E) has to undergo at least a few days of modifications to switch between Falcon 9 and Heavy.

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Regardless, the next two Falcon Heavy launches will be well worth the wait. SpaceX’s FCC filings indicate that the center core may travel nearly 1000 km (600 mi) East of Pad 39A to land on drone ship OCISLY after launch, smashing the previous record attempt – during the June 2016 launch of Eutelsat 117WB – of ~700 km (430 mi). That Falcon 9 booster – albeit a less-powerful Block 2 variant – was unsuccessful in its landing attempt, running out of oxidizer seconds before landing. Falcon Heavy’s debut center core also happened to suffer a wholly different but no less fatal anomaly during landing, causing it to miss the drone ship and slam into the Atlantic Ocean at almost half the speed of sound (300 mph/480 km/h).

Known for their rocket performance estimates, NASASpaceflight forum user “Orbiter” first pointed out the impressive distance – gathered by mapping coordinates included in SpaceX’s Jan. 28th FCC filing – and estimated that the Falcon Heavy center booster flying a trajectory as implied could be traveling as fast as ~3.5 km/s (2.2 mi/s) at main engine cut-off (MECO), the point at which the booster separates from the upper stage and fairing. This would be a nearly unprecedented velocity for any Falcon booster, let alone a booster with plans to land after launch. Falcon 9 MECO typically occurs at velocities between 1.5 and 2.5 km/s for recoverable missions, while even the recent expendable GPS III launch saw F9 S1’s engines cut off around 2.7 km/s.

Whether that MECO velocity estimate is correct, Falcon Heavy’s NET March launch of the ~6000 kg (13,300 lb) Arabsat 6A satellite is likely to be an exceptionally hot reentry and recovery for the center core, while the rocket’s duo of side boosters will attempt a repeat of the debut mission’s spectacular double-landing at LZ-1.


Check out Teslarati’s newsletters for prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket launch and recovery processes!

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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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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.

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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.

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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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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.

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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.

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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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