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SpaceX’s next-gen Falcon Heavy closer to reality as side booster leaves factory

SpaceX's next Falcon Heavy launch is one step closer to reality after a side booster was spotted eastbound in Arizona. (Reddit u/beast-sam)

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A duo of rocket spottings on November 9th and 10th confirm that SpaceX’s next Falcon Heavy rocket – an amalgamation of three Falcon 9 boosters, an upper stage, and extensive modifications – is already in the late stages of manufacturing and is nearing the beginning of integrated structural and static fire testing.

As of now, this Falcon Heavy side booster could end up supporting either or both of two near-term launch contracts in place for the rocket, communications satellite Arabsat 6A or the US Air Force’s second Space Test Program (STP-2) launch

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The question of the hour – at least for Falcon Heavy – is which of those two available payloads will be atop the rocket on its first truly commercial launch. While suboptimal, a few general characteristics of each payload, SpaceX’s history of commercial launches, and Falcon Heavy itself can offer a hint or two.

Triple the rocket, triple the trouble

Thanks in large part to the fact that the first integrated Falcon Heavy was composed of two relatively old Falcon 9 booster variants and a center core that was quite literally a one-off rocket, the process of reenginering and building another Falcon Heavy rocket off of the family’s newest Block 5 variant has likely been far harder than simply building another Falcon Heavy. Although all three original Falcon Heavy boosters (B1023, B1025, and B1033) were in the same league as Block 5, their Block 2 and Block 3 hardware was designed for approximately 10% less thrust and are almost entirely different vehicles from the perspective of structures and avionics.

Perhaps even more importantly, it’s unknown whether Falcon Heavy Block 1 (for lack of a better descriptor) was designed with serious reusability in mind, at least in the same sense as Falcon 9 Block 5 was. For instance, a major portion of the rocket’s extreme complexity and difficulties lies in the basic need to transmit three times as much thrust through the center core. To do that and do it without rocket-powered separation mechanisms, SpaceX had to develop structural attachments and connections capable of surviving unbelievable mechanical and thermal stresses for minutes on end.

 

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Clearly, this was an unfathomably difficult problem to solve in such a manner that Falcon Heavy would work at all the first time. Factor in the strategic need for those same components to survive repeated cycles of those stresses with minimal refurbishment in between and the problem at hand likely becomes a magnitude more difficult, at least. In large part, this helps to explain why there will end up being a minimum of 11-12 months between Falcon Heavy’s first and second launches.

Arabsat or STP?

Over the course of SpaceX’s last 2-3 years of commercial launch activity, the company and its customers have demonstrated time and time again a reliable pattern: commercial customers (in the sense of private entities) are far more willing to take risks with new technologies than SpaceX’s government customers. NASA’s Commercial Resupply Services is the exception for the latter group but also has no Falcon Heavy launch contracts. For Falcon Heavy, there are thus main three options at hand.

  1. Arabsat 6A launches first with 1-2 flight-proven boosters; the Air Force’s STP-2 mission flies on an all-new Falcon Heavy 4-6 months later.
  2. SpaceX builds entirely new Falcon Heavy rockets for both customers, requiring four new side boosters and two new center cores.
  3. STP-2 launches first on an all-new Falcon Heavy; Arabsat 6A launches second on the first flight-proven Falcon Heavy after 6+ months of additional delays.

 

Arabsat is far more likely to accept – for a significant discount – a ride aboard the first flight-proven Falcon Heavy, especially if it means preventing more major launch delays. If the Falcon Heavy side booster spotted eastbound last week is a refurbished Block 5 booster rather than a new rocket, than option 1 is the easy choice for most probable outcome. The real pack leader for Falcon Heavy Flight 2, however, will be the completion of a new Block 5 center core and its shipment to Texas for structural and static fire testing.

Time will tell. For now, a completed Falcon Heavy side booster is the best sign yet that SpaceX may manage the rocket’s second launch in the first quarter of 2019, whichever launch that may be.

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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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Elon Musk

SpaceX files confidentially for IPO that will rewrite the record books

SpaceX files confidentially for a record-breaking IPO targeting a $1.75T valuation and $80B raise, driven by Starlink growth and its xAI merger.

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Elon Musk’s rocket and satellite company submitted its draft registration to the U.S. Securities and Exchange Commission today for an initial public offering, targeting June at a $1.75 trillion valuation. This would be the largest in history.

SpaceX has filed confidentially with the SEC, first reported by Bloomberg. SpaceX would be valued above every S&P 500 company except Nvidia, Apple, Alphabet, Microsoft, and Amazon.

The filing uses a confidential process that allows companies to work through SEC disclosures privately before initiating a public roadshow. With a June target, official details through a formal prospectus is expected to go public in April or early May, after which SpaceX must wait at least 15 days before beginning investor marketing.

SpaceX IPO is coming, CEO Elon Musk confirms

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While SpaceX is best known for its Falcon 9 and Starship rockets, the $1.75 trillion valuation is anchored by Starlink, its satellite internet service. Starlink ended 2025 with 9.2 million subscribers and over $10 billion in revenue, which is a figure analysts project could reach a staggering $24 billion by the end of 2026. A February all-stock merger with xAI, Musk’s artificial intelligence venture, further boosted the valuation.

SpaceX officially acquires xAI, merging rockets with AI expertise

Bank of America, Goldman Sachs, JPMorgan Chase, and Morgan Stanley are lined up as senior underwriters. SpaceX is also considering a dual-class share structure to preserve insider voting control, and plans to allocate up to 30% of shares to retail investors, which is roughly three times the typical norm.

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Elon Musk

Elon Musk hints at “official ceremony” with throwback photo to close Tesla Model S, Model X chapter

Elon Musk promises an official ceremony to mark the end of Tesla Model S and Model X production.

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lon Musk at the Tesla Model S production launch at the Fremont factory, June 2012. Photo shared by Musk on X, March 2026.

Tesla has officially begun winding down production of the Model S and Model X, sending farewell emails to U.S. customers on March 27 and updating the website to reflect the end of the line. Shoppers visiting Tesla.com now find only a limited set of Model S and Model X inventory units available for purchase, with no option to configure  a new factory build. The move formalizes what CEO Elon Musk announced on the company’s Q4 2025 earnings call in January, when he said it was “time to basically bring the Model S and X programs to an end with an honorable discharge.”

Musk posted on X a throwback photo of himself speaking at the Model S production launch in 2012, and noting “We will have an official ceremony to mark the ending of an era. I love those cars.”

The mention of an official ceremony is notable. Tesla has not held a formal farewell event for a vehicle before, and Musk’s wording suggests this will be something deliberate rather than a quiet line shutdown. Given that Musk’s X post shows a photo of him on stage with a microphone in front of an audience at the Fremont factory, it wouldn’t be too far-fetched to expect a closing ceremony to take place at the same location. Perhaps? Whether it becomes a public event, a private gathering for employees, or a livestreamed moment on X remains to be seen.

The Model S first went on sale nearly fifteen years ago and was Tesla’s first fully in-house designed vehicle, proving that an electric car could be fast, desirable, and capable of long distance on a single charge. The Model X followed in 2015, turning heads with its unmistakable and distinctive falcon-wing doors, while becoming one of the first all-electric SUVs on the market. Tesla’s two flagship vehicles would ultimately push legacy automakers to take all-electric transportation seriously and help fund development of the more affordable Model 3 and Model Y.

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By 2025, however, both models had been reduced to a rounding error in Tesla’s sales figures. Musk was direct about what comes next, stating “We are going to convert that production space to an Optimus factory. It’s part of our overall shift to an autonomous future.”

Elon Musk’s $10 Trillion robot: Inside Tesla’s push to mass produce Optimus

That shift is already underway. Tesla officially started Optimus Gen 3 production at its Fremont factory in January 2026, with the line targeting a run rate of one million units per year. The Gen 3 robot features 22 degrees of freedom per hand, runs on Tesla’s AI5 chip, and shares the same neural network architecture as Full Self-Driving. A dedicated Optimus factory at Gigafactory Texas is also under construction, with a planned annual capacity of 10 million units. The production lines that once built the Model S and Model X are being converted to support that ramp.

Tesla confirmed it will continue to support existing owners with service, software updates, and parts for as long as people own the vehicles. For buyers still interested in a new example, remaining U.S. inventory is discounted and the window is closing fast.

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Elon Musk

Elon Musk announces disappointing Tesla Optimus update

In a post on X on March 31, Musk stated that Optimus 3 is mobile but requires some finishing touches before it is ready to be shown to the world. This update comes on the final day of the first quarter, a period when Tesla had previously signaled expectations for a Gen 3 reveal.

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Credit: Tesla China

Elon Musk announced a disappointing update to the unveiling of Tesla Optimus and its third-generation iteration, missing a timeline it aimed to hit in the first quarter of the year.

Musk has confirmed that the highly anticipated Optimus Gen 3 humanoid robot is already walking around and operational, yet the public unveiling will face a short delay as the company applies final refinements.

In a post on X on March 31, Musk stated that Optimus 3 is mobile but requires some finishing touches before it is ready to be shown to the world. This update comes on the final day of the first quarter, a period when Tesla had previously signaled expectations for a Gen 3 reveal.

The announcement follows reports of Optimus Gen 3 appearing at the Tesla Diner in Los Angeles, where it was observed serving and moving about until sunset. Images and videos shared by observers captured the robot in action, highlighting its progress in real-world mobility.

Tesla had aimed to showcase the production intent version of Optimus Gen 3 during the first quarter of 2026, positioning it as a major step toward factory deployment and eventual commercial availability. Musk has described the robot as featuring advanced capabilities, including highly dexterous hands with significant degrees of freedom, powered by Tesla’s AI systems for complex tasks.

This minor postponement aligns with Tesla’s iterative approach to development. Earlier statements from Musk indicated that Gen 3 would represent the most advanced humanoid robot yet, designed primarily for internal factory use before scaling to external customers.

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Elon Musk’s $10 Trillion robot: Inside Tesla’s push to mass produce Optimus

Production timelines point toward low-volume output starting in the summer of 2026, with volume ramp-up targeted for 2027. The delay underscores the company’s commitment to quality over speed, ensuring the robot meets rigorous standards for safety and performance in practical environments.

Optimus represents a cornerstone of Tesla’s long-term vision beyond electric vehicles. Musk has repeatedly emphasized that successful humanoid robotics could transform industries by addressing labor shortages and enabling new forms of productivity.

Competitors in the space continue to advance their own platforms, yet Tesla’s vertical integration, from custom actuators to end-to-end AI training, positions Optimus as a potential leader. Community reactions on social media range from excitement over visible progress to impatience with shifting timelines, a familiar pattern in Tesla’s innovation journey.

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Investors and enthusiasts view Optimus as critical to Tesla’s valuation, potentially surpassing its automotive business in scale. With the robot already demonstrating walking and basic interactions, the finishing touches likely involve software polishing, hardware fine-tuning, and reliability enhancements.

Musk’s update suggests the reveal could arrive in the coming weeks or months, maintaining momentum toward broader deployment.

As Tesla pushes the boundaries of physical artificial intelligence, this latest development keeps Optimus in the spotlight. The company continues to prioritize rapid iteration while delivering on its promises to shareholders and customers. The robotics revolution at Tesla appears closer than ever, promising profound impacts on manufacturing, services, and daily life in the years ahead.

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