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SpaceX’s Elon Musk talks next goals for Falcon rocket reusability
CEO Elon Musk has reiterated that SpaceX is still pursuing a major rocket reuse milestone he originally set for the company several years ago and revealed that its Falcon rockets could ultimately soar far beyond it.
Musk has been talking publicly about reusable rockets for well over a decade but the first hard numbers linked to real hardware came with the debut of Falcon 9’s Block 5 upgrade in May 2018. In a conference call with reporters, Musk famously revealed that the Block 5 upgrade incorporated design changes that would ultimately allow SpaceX to reuse orbital-class Falcon boosters at least ten times each. An upper bound of 100+ flights per booster would also be possible with regular maintenance and part replacements every ten or so launches.
Since the upgrade’s May 11th, 2018 launch debut, Falcon 9 and Heavy Block 5 rockets have completed 37 launches – all successful – with only one in-flight anomaly, a March 2020 engine failure that prevented booster recovery but didn’t preclude mission success. Excluding three flawless Falcon Heavy launches, SpaceX’s 34 Falcon 9 Block 5 launches were collectively completed by 11 boosters – an average of >3 launches per rocket. In fewer words, SpaceX has accumulated a vast wealth of data with which it can judge the Block 5 design and CEO Elon Musk has some choice observations more than two years after his Block 5 press conference.
In the simplest possible terms, Musk’s August 19th comments strongly suggest that the Block 5 upgrade has more than met the goals laid out for it back in 2018.
The fact alone that the average Falcon 9 Block 5 booster (even including one expendable mission) has launched more than three times is a major credit to the design. At the same time, SpaceX flew the same booster for the sixth time just days ago and achieved the fifth launch of three separate Falcon 9 boosters between March and August of 2020.
Now, with all that experience in hand and a Falcon 9 Block 5 booster already 60% of the way to the ten-flight reuse milestone, Musk says that “100+ flights are possible” and that “there isn’t an obvious limit.” While “some parts will need to be replaced or upgraded” to achieve dozens or hundreds of booster reuses, Musk says that SpaceX “almost never need[s] to replace a whole [Merlin 1D] engine.
Given that a Falcon 9 booster’s nine M1D engines are likely the most difficult part of each rocket to quickly and safely reuse, it’s extremely easy to believe that individual boosters can launch dozens – if not hundreds – of times with just a small amount of regular maintenance and repairs. In that sense, SpaceX has effectively achieved Musk’s long-lived dream of building a rocket that is (more or less, at least) approaching the reusability of aircraft.
Of course, even 100-flight Falcon boosters would still be at least one or two orders of magnitude distant from most modern aircraft, but that would still be a vast improvement over any other launch vehicle in history (especially including the Space Shuttle).
Musk says that SpaceX is still actively pushing to fly a Falcon 9 booster ten times and Starlink missions – allowing the company to mitigate risk on its own launches – will leave plenty of opportunities. If SpaceX can fly Falcon 9 booster B1049 every 60 days on average, the company could hit that ten-flight milestone as early as Q2 2021.
The SpaceX CEO also responded to a classic head-in-the-sand claim from traditional aerospace companies like United Launch Alliance (ULA), refuting the theoretical supposition that booster reuse “doesn’t make sense” until ten-flight reuse is achieved. Instead, Musk says that SpaceX only needs to fly each booster three times to ensure that booster reuse is cheaper than just building new rockets.
In short, despite the ad hoc rationalizations competitors continue to use to excuse years of denial and laurel-resting, SpaceX is routinely reusing rockets, saving major resources by doing so, and has still just barely scratched the surface of what is ultimately possible.
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Tesla has lost its Model Y Program Manager, he announced on LinkedIn, marking the second major departure from the company today.
Emmanuel Lamacchia has been in the role for 4 years and 7 months, responsible for the rollout of the all-electric crossover in several markets.
The Model Y became the best-selling vehicle in the world for two years under Lamacchia’s watch, making this a huge loss for the company. However, it seems the decision was made under Lamacchia’s own initiative.
He confirmed his decision on LinkedIn:
“After 8 incredible years, I’m moving on from Tesla.
What a journey it’s been… from leading NPI for Model 3 and Model Y variants to becoming the Vehicle Program Manager for Model Y, the best-selling car in the world!
Leading the All-New Model Y launch was the highlight: converting all 4 factories across 3 continents in just 2 weeks. Something that had never been done before in the auto industry.
To the teams who made this possible: you should be incredibly proud. This achievement belongs to you: the engineers, designers, buyers, and associates in Fremont, Shanghai, Berlin, and Austin who turned an impossible timeline into reality.
Grateful to the leaders who trusted me with programs that stretched my capabilities and to the cross-functional partners who showed me that great solutions come from collaboration, not hierarchy.
Tesla taught me how to move fast without breaking things and how to scale from prototypes to millions of units.
Excited for what’s next. More to share soon.”
It marks the second major program loss for Tesla today, as it also bid farewell to Cybertruck and Model 3 Program Manager Siddhant Awasthi, who said he left voluntarily in “one of the hardest decisions of his life.”
Lamacchia was at Tesla for just a shade under eight years, and previously worked for Rolls-Royce for roughly the same amount of time.
After the loss of both Lamacchia and Awasthi today, Tesla has lost a handful of key executives in 2025, including:
- David Imai, Director of Design
- David Lau, VP of Software Engineering
- Mark Westfall, Head of Mechanical Engineering
- Prashant Menon, Regional Director in India
- Vineet Mehta, Head of Battery Architecture
- Omead Afshar, VP/Head of Sales and Manufacturing in North America
- Milan Kovac, Head of Optimus Team
- Jenna Ferrua, Director of HR
- Troy Jones, VP of Sales, Service, and Delivery
- Pete Bannon, VP of Hardware Engineering
- Piero Landolfi, Director of Service
News
Tesla prepares to expand Giga Texas with new Optimus production plant
Drone operator Joe Tegtmeyer recognized Tesla construction crews performing ground leveling and clearing efforts at the plant earlier today.
Tesla is preparing to expand Gigafactory Texas once again with a brand new facility that will house the eventual manufacturing efforts for Optimus, its humanoid robot.
It is already building some units on a Pilot line at the Fremont Factory in Northern California, but Tesla is planning to build the vast majority of its Optimus project at Gigafactory Texas.
Tesla Optimus gets its latest job, and it’s not in the company’s factories
It will build one million units per year in Fremont, but CEO Elon Musk said the company would build 10 million units every year in Texas at a new building at Giga Texas.
Musk said:
“I think there could be tens of billions of Optimus robots out there. Um, now obviously it’s very important we pay close attention to safety here. Then a 10 million unit uh per year production line here the I don’t know where we’re going to put the 100 million unit production line. on Mars. Maybe on Mars, I don’t know.”
Evidently, Tesla is ready to begin thinking about the production efforts of Optimus beyond a theoretical standpoint and is starting to prepare for the construction of the manufacturing plant on Giga Texas property.
Drone operator Joe Tegtmeyer recognized Tesla construction crews performing ground leveling and clearing efforts at the plant earlier today:
Giga Texas News!
A brand-new, stand-alone factory is starting construction! This follows the Shareholders meeting & info that a 10-million-per-year @Tesla_Optimus production facility “on the Giga Texas campus” will be built & enter into production in 2027!
Here are some… pic.twitter.com/7ig5DohfOt
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) November 10, 2025
Production is still slated for 2027, at least at Gigafactory Texas. As previously mentioned, the company is building some units in Fremont for the time being, at least until subsequent versions of the Optimus project advance.
Tesla has done a great job of advancing Optimus forward, but it also has truly grand expectations for the project.
Musk said it could potentially be the biggest product in the history of the planet, as it will revolutionize the way humans perform tasks, probably eliminating monotonous tasks from everyday life.
Tesla revealed its first customer for the all-electric Semi truck after it launches next year. Who it truly is should not be a surprise.
The Semi is going to finally start deliveries to new companies outside of Tesla’s pilot program starting in 2026. The company has been building a dedicated production facility in Reno, Nevada, that has finally taken shape, but Tesla was evidently not finished with the Semi’s development.
Last week at the Annual Shareholder Meeting, Tesla said it had implemented some new designs into the Semi, helping with efficiency, updating its design, and making it a more suitable vehicle for hauling loads, as the changes also helped increase payload.
Tesla has obtained a lengthy list of companies that have committed to implementing the Semi in their own fleets, hoping to bring their logistics lineups up to date with electric powertrains and autonomous technologies.
While it is already operating a pilot program with PepsiCo. and Frito-Lay, Tesla will expand to other businesses, primarily using it internally after its launch.
Head of the Semi program at Tesla, Dan Priestley, said the company would be the first user of the vehicle after its launch next year. It has been using it to a certain extent, but the company has not been able to completely abandon gas haulers.
Instead, it will implement the Semi into its fleet for more sustainable vehicle logistics starting next year:
Tesla will be the first customer as we electrify our supply chain. This includes Texas operations.
— Dan Priestley (@danWpriestley) November 7, 2025
Tesla has already received orders for the Semi from a variety of large companies, including Walmart, Sysco, Anheuser-Busch, UPS, DHL, J.B. Hunt, among others.
Many analysts see the Tesla Semi as a major contributor to future growth and increasing value within the company, especially from a Wall Street perspective. Some firms say the Semi is one of several near and medium-term contributors to the company increasing its market cap.
Cantor Fitzgerald is just one of those firms, as last week it explicitly listed the Semi as a catalyst.
Analyst Andres Sheppard said, “Overall, we remain bullish on TSLA over the medium to long term. We continue to see meaningful future upside from Energy Storage & Deployment, FSD, Robotaxis/Cybercab, Semis, and Optimus Bots.”
Tesla loses Model Y program manager in second blow in single day
Tesla prepares to expand Giga Texas with new Optimus production plant
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