The first commercial launch of SpaceX’s Falcon Heavy rocket – this time in a Block 5 configuration – is as few as ten days away from a targeted window beginning at 6:36 pm EST (22:36 UTC), April 7th. That target hinges on whether Falcon Heavy is ready and able to roll out to Pad 39A and successfully conduct its first integrated static fire, currently scheduled on April 1st.
The payload for this mission – communications satellite Arabsat 6A – had its original Lockheed Martin manufacturing and SpaceX launch contracts signed back in the first half of 2015, while the 6000 kg (13,200 lb) spacecraft was effectively completed once it was shipped from California to Florida at the start of 2019. After approximately 12 months of delays from an original launch target shortly after Falcon Heavy’s 2018 debut, Arabsat 6A’s four-year journey will hopefully reach completion in a geostationary transfer orbit. At the same time, the US Air Force says that it will be watching this launch – and the one meant to follow soon after – as a critical test along the path to fully certifying the powerful rocket for military launches.
As a pathfinder for an unproven rocket, SpaceX’s first Falcon Heavy launch suffered a number of likely minor to moderate anomalies as company engineers and technicians learned for the first time how the rocket actually behaves in the real world, under real-world conditions and operations. Case in point, the first integrated Falcon Heavy was taken through its first wet-dress rehearsal – in which the vehicle is filled with a
Despite the invaluable experience gained by those orchestrating the launch and those who built the vehicle, Falcon Heavy’s second launch may result in similar teething pains, particularly due to the fact that the rocket’s complete upgrade to Block 5 hardware likely necessitated significant design changes across the board. In other words, the rocket SpaceX aims to launch in early April may be quite a bit different from the vehicle that launched 14 months prior, creating much of the same uncertainty inherent in the first launch(es) of any new rocket. Still, many of the complex boosters’ connection and separation mechanisms that were flight-tested for the first time that February 
“Again, I don’t want to tempt fate. But this is a much stronger octaweb structure. It’s made of
“Biggest process change [for Block 5] was eliminating Tig welding of the thrust structure or “Octaweb” and the move to a bolted design but this made it much easier and faster to produce overall as well.” – SpaceX VP of Production Andy Lambert, April 2018
A step further, SpaceX CEO Elon Musk has indicated that one major section of Block 5 upgrades – moving from a welded to a bolted thrust structure (i.e. octaweb) – was expected to be a boon for Falcon Heavy, while also making octawebs far easier to manufacture, assemble, and even disassemble. According to Musk, new bolted octawebs are also “dramatically” stronger, a boon for Falcon Heavy boosters – particularly the center core – that need to survive forces multiple times stronger than those subjected upon Falcon 9 first stages.
Meanwhile, according to comments made by Air Force officials to Spaceflight Now, the USAF is looking at SpaceX’s Arabsat 6A and subsequent STP-2 Falcon Heavy launches as critical steps along the way to fully certifying the rocket for valuable military payloads. Currently, the only option available for military and NRO payloads past a certain weight or in need of exceptionally high-energy orbits is ULA’s Delta IV Heavy rocket, an extremely expensive ($300M+ per launch) rocket with a bad track record of schedule reliability.
An Air Force spokesperson this week confirmed the agreement to use previously-flown side boosters for the STP-2 mission. The center core will be new for the Arabsat 6A and STP-2 launches.
“This provides an early opportunity for the Air Force to understand the process for using previously-flown hardware with the goal to open future EELV missions to reusable launch vehicles,” the spokesperson said in response to an inquiry from Spaceflight Now.
SpaceX’s Falcon Heavy rocket could launch on its first commercial flight as soon as April 7. SpaceX will re-fly the side boosters on a Falcon Heavy launch this summer in a key demonstration for the Air Force to move closer to certifying reused rockets. https://t.co/guc7yaE7sH pic.twitter.com/FyaIS3Mlnf— Spaceflight Now (@SpaceflightNow) March 16, 2019
Given that STP-2 will need to reuse both of the Arabsat 6A Falcon Heavy’s side boosters, the USAF official also specifically noted that the military branch would be examining SpaceX’s refurbishment processes and the performance of the flight-proven stages with the intention of ultimately allowing reused rockets to launch military satellites. As such, the successful launch, landing, refurbishment, and re-launch of both Falcon Heavy side boosters (B1052 & B1053) will be doubly critical for SpaceX.
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News
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.
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.
We’re excited for Falcon 9 and Dragon to launch @NASA’s Crew-15, 16, and 17 missions to the @Space_Station from Florida https://t.co/Qm16vVK9F3 pic.twitter.com/drg3s7GtuM
— SpaceX (@SpaceX) September 18, 2026
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.
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.
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.
The Giga Texas Optimus Factory latest update … construction keeps moving fast!
Steel assembly is now only about 5 column grids from the north perimeter beam. Concrete is going in on the three upper floors, rebar is still being laid for more pours, and footing / grade-beam work… pic.twitter.com/qvFPvwnYzW
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) September 17, 2026
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.
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.
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.
NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded
New drone video shows Tesla’s Optimus Factory reaching a turning point
