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SpaceX nails first reuse of its next-gen Falcon 9 Block 5 rocket

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SpaceX has successfully reused the first Falcon 9 Block 5 booster less than three months after the rocket’s major reliability and reusability upgrade debuted. This milestone may feel small in the shadow of SpaceX’s accomplishments over the last ~18 months but make no mistake: the second flight of a Block 5 booster is by far the company’s most significant achievement in recent years.

First and foremost, this is by no means meant to demean the awe-inspiring reality of what SpaceX has managed over the last several years, which includes the first successful Falcon 9 landing, the first commercial orbital-class rocket reuse (also Falcon 9), and the first commercial reuse of an orbital spacecraft (Cargo Dragon), and many others. Rather, it really is the case that the first Block 5 reuse is one of the most important things ever done by SpaceX.

 

Why is this launch so significant?

As noted by webcast host and engineer Lauren Lyons, the second successful drone ship recovery of Falcon 9 Booster 1046 (B1046) paves the way for the SpaceX’s first-ever third launch of the same rocket. The number “3” may not immediately feel significant, but in the case of Falcon 9, the third reuse of a booster has always remained out of reach for older versions of the rocket, walled off by the exponentially greater cost and effort required to refurbish non-Block 5 rockets after their first reuse. Block 5 is different, and that’s by design.

Put very simply Falcon 9 Block 5 is an iteration of the venerable launch vehicle that best represents SpaceX moving from reusable rockets as experimental prototypes to a successfully developed and implemented technology – with Block 5, SpaceX is effectively proclaiming that Falcon 9’s reusability design has been completed and optimized thanks to dozens of rocket landings (28) and reuses (15).

 

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With the third reuse now explicitly on the table for B1046 “later this year”, Falcon 9 has broken a two-launch ceiling that long loomed over its older predecessors. The third reuse will pave the way for the 4th, 5th, 10th, 50th … reflight of individual Falcon 9 boosters, an absolutely integral requirement for SpaceX to achieve its ultimate goals of sustainably colonizing the solar system – starting with Mars – and thus ‘backing up’ humanity.

B1046’s second suborbital jaunt and landing aboard drone ship Of Course I Still Love You will almost undoubtedly be a turning point in the future history of SpaceX. For those that missed the stream or just want to watch again, catch the milestone launch below.


For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet (including fairing catcher Mr Steven) check out our brand new LaunchPad and LandingZone newsletters!

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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SpaceX set to launch astronauts and a classified Falcon Heavy mission on the same day

SpaceX plans three launches Thursday, including Crew-13 astronauts and Falcon Heavy’s first classified NRO mission.

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Crew Dragon sits atop Falcon 9 at sunrise on Cape Canaveral's pad 40, less than a day before four astronauts are set to launch to the ISS. (Credit: SpaceX)
Crew Dragon sits atop Falcon 9 at sunrise on Cape Canaveral's pad 40, less than a day before four astronauts are set to launch to the ISS. (Credit: SpaceX)

SpaceX is lining up one of the busiest single days in its history, and the company offered a preview on Wednesday morning with a simple post on X: “Sunrise at pad 40.” The video and photos show Falcon 9 standing at Space Launch Complex 40 at Cape Canaveral, roughly a day before it is scheduled to carry four astronauts to the International Space Station.

That launch is only the first of three SpaceX missions planned for Thursday, October 1, across both coasts.

Crew-13 is targeting liftoff at 11:10 a.m. ET, with a backup opportunity Friday at 10:47 a.m. ET. NASA astronaut Jessica Watkins will command the mission, with NASA’s Luke Delaney as pilot and Canadian Space Agency astronaut Joshua Kutryk and Roscosmos cosmonaut Sergey Teteryatnikov serving as mission specialists. According to NASA, Dragon is set to dock with the forward port of the station’s Harmony module around 8 p.m. ET, less than nine hours after launch. Watkins is the only member of the crew who has flown before, and Kutryk will become the first Canadian to reach orbit through NASA’s Commercial Crew Program.

The Falcon 9 booster is flying for the third time after supporting Crew-12 and a Starlink mission, and it will attempt a landing at Landing Zone 40 beside the pad. That site made its debut in February when the Crew-12 booster touched down there, as Teslarati reported at the time. Crew-13 will relieve the Crew-12 astronauts, who have been aboard the station since the middle of February.

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On the West Coast, another Falcon 9 is scheduled to lift off from Vandenberg Space Force Base in a window running from 2:18 to 3:16 p.m. ET, a flight NASASpaceflight lists as a Transporter rideshare mission.

The day is set to close at 11:53 p.m. ET, when Falcon Heavy launches from Launch Complex 39A with NROL-97, the first National Reconnaissance Office payload ever to fly on the rocket. SpaceX rolled the vehicle out to the pad Tuesday night. Its two side boosters, which previously flew GOES-U, ViaSat-3 F3 and NASA’s Roman Space Telescope, will return to Landing Zones 1 and 2, while a new center core will be expended in the Atlantic. The Roman launch took place on August 30, so NROL-97 will come barely a month later as Falcon Heavy’s third flight of 2026 and 14th overall.

NASA taps SpaceX to launch the telescope that could unlock new worlds

If all three Florida boosters land as planned, it would be the first time the Space Coast has seen landings at LZ-40, LZ-1 and LZ-2 on the same day, according to the Orlando Sentinel, which has warned residents in Brevard, Orange and Volusia counties that more than one sonic boom is possible.

The schedule arrives just three days after Starship reached orbit for the first time on Flight 14 from Starbase, Texas, deploying 26 Starlink V3 satellites. If Thursday’s missions stay on time, SpaceX will have flown Starship, Falcon 9 and Falcon Heavy from four different pads in about four days.

Crew-13 is also the start of a longer run for Dragon. NASA recently added Crew-15, Crew-16 and Crew-17 to SpaceX’s contract in a $946 million modification, keeping Dragon as the agency’s only operational ride to the station while Boeing’s Starliner remains grounded.

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Tesla Cybercab and Semi have more in common than you might think

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Credit: Tesla

Although the two vehicles are built for completely different use cases, Tesla utilized engineering expertise while developing both the Cybercab and Semi to build a thermal architecture that would fit both vehicles. Of course, with some slight revisions.

The development was noted by Lars Moravy and Dan Priestley last week at Tesla’s Semi Handover event in Sparks, Nevada, where the company showed off its dedicated production facility for the Class 8 truck.

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Tesla’s decision to develop one thermal architecture for both the Cybercab and Semi is one of the more revealing engineering choices in the company’s 2026 lineup:

“We designed it at the same time we designed the Cybercab and we said okay we’re going to take our most efficient vehicle and our biggest vehicle and we’re going to take one thermal system and make it work for both.”

Core parts, meaning the compressor, pumps, and heat exchangers, are shared, with only modest changes to cooling-loop sizing and a larger radiator on the truck. The result, they said, is a compressor and thermal stack already proven across millions of miles, delivering “reliability from day one.”

Priestley also highlighted a practical payoff of the indirect design:

“There’s no AC lines, there’s no refrigerant lines…It comes from the factory fully charged, sealed with refrigerant, and it just exchanges coolant. It doesn’t actually run refrigerant up to the front of the vehicle.”

This eliminates potentially leak-prone plumbing that would otherwise require hands-on service, reducing overall uptime and potentially cutting into business margins. The megamanifold runs cabin HVAC and every powertrain heating and cooling loop at once, recapturing waste heat from motors and the battery instead of dumping it the way a diesel engine does.

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The approach is just the latest chapter in a continuing story of stretching thermal solutions across wildly different vehicles. Model Y’s Octovalve evolved into the Super Manifold used on Cybertruck, and later Model S/X refreshes. Cybercab then introduced Supermanifold V3, which Tesla says is 80 percent automated to build and 38 percent more efficient than typical automotive thermal systems.

Tesla has done the same with the 4680 cells, both being utilized in the Cybertruck and Semi, and with heat-pump compressors that Priestley noted were already common across the passenger-car fleet.

Concurrent development of crucial vehicle elements buys scale and reliability that a truck-only thermal system could not match. High-volume passenger car parts are cheaper and more accessible, which can give fleets a sealed, low-maintenance loop of operation from their first day of operation.

For owners and operators, that translates into less energy spent on cabin heat in the colder months, fewer refrigerant-related repairs, and a thermal architecture already stress-tested at passenger-car volumes before the first high-volume Semi left the lines in Nevada.

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Elon Musk weather update tips Tesla Roadster speculation into Plaid Mode

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Credit: Tesla

Tesla CEO Elon Musk certainly tipped off some details of the Tesla Roadster event with a broadening of information regarding the company’s decision to delay the unveiling for two weeks.

For years, people have speculated about what the Roadster will be capable of. While there have been plenty of things said about what it *could* do, we have not seen or been told by Tesla what it will actually be capable of.

However, over the past few days, Tesla’s weather updates have truly pushed the speculation into Plaid Mode, basically all but confirming the car will have some sort of aerial capability — whether that would be hovering or fully flying remains to be seen — but it definitely seems that it will be able to leave the ground intentionally.

“Because this event can only be held outdoors…”

Tesla posted on Monday that it would delay the Roadster event until October 15, and it indicated that it had to do this because the event “can only be held outdoors.”

With the potential SpaceX collaboration to develop cold-gas thrusters that will help the vehicle go airborne, doing this indoors is probably not a safe, or even plausible, possibility.

FAA Airspace Restriction

The FAA gave Tesla a Temporary Flight Restriction (TFR) for 10,000 feet above ground level, much higher than the typical 2,000-foot restrictions that are usually placed at SpaceX’s McGregor, Texas site.

Tesla Roadster event requires restricted airspace, and the FAA obliges

Some have said that this massive increase is due to Tesla’s need to restrict unauthorized drone use for spying on the event.

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Elon Admits High Winds

“Due to high winds, the new Roadster demo is postponed by 2 weeks,” Musk said in a post on X yesterday.

A reply reading, “What’s strong wind got to do with a car demo with four grounded wheels?” was directly below Musk’s post, satirically and sarcastically probing for more details.

All signs are pointing toward an aerial demonstration for the Roadster.

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