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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

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.

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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.

 

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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Why SpaceX is finishing another space-internet system that isn’t Starlink

SpaceX launched three final O3b mPower satellites Sunday, finishing a lesser known SES satellite network.

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SpaceX had an 87 minute window opening at 2:49 p.m. Eastern on Sunday to fly a Falcon 9 out of Cape Canaveral carrying the final three satellites for SES’s O3b mPower constellation, a project that has taken more than a decade to finish since Boeing and SES first signed SpaceX on for the work.

Unlike the thousands of Starlink satellites SpaceX has stacked into orbit over the years, O3b mPower flies in a different neighborhood entirely. The three new satellites, tagged F11, F12 and F13, are headed for medium Earth orbit at roughly 5,000 miles up, more than ten times higher than Starlink’s shell around 340 miles but still a small fraction of the 22,000 miles where old school geostationary satellites sit. That middle position is the whole point, because a satellite that far out needs far fewer siblings to blanket the globe than a low orbit constellation does. Essentially, SES only needed 13 satellites total to build a network offering quick, steady service that used to require thousands of spacecraft.

With most people having heard plenty about Starlink and almost nothing about O3b mPower, SES and SpaceX already blend the two networks for some customers. Both SpaceX and SES sell satellite broadband, but they’re aimed at different buyers. Starlink is built for volume, direct to consumers, RVs, homes, small businesses, plus a growing aviation and maritime business. O3b mPower skips consumers entirely and sells enterprise grade connectivity to airlines, cruise lines, offshore energy operators, telecoms needing backhaul, and governments, priced and provisioned more like a dedicated circuit.

A 2023 partnership lets cruise ships combine Starlink’s speed with O3b mPower’s steady capacity depending on what a ship needs at a given moment. Sunday’s completed 13 satellite constellation effectively finishes the medium orbit half of that pairing, years after.

Sunday’s mission was already a something on SpaceX’s manifest well before O3b mPower entered the picture. This flight marked its 29th trip to orbit, a history that includes two crewed Axiom missions, the European Space Agency’s Euclid telescope and 22 separate Starlink batches. SpaceX has landed boosters on the droneship A Shortfall of Gravitas so often that Sunday’s touchdown attempt, if it went as planned, was set to be the 661st successful Falcon booster landing to date.

For a company that pushed the Starlink constellation past 11,000 satellites back in August, almost entirely through bulk launches from California, Sunday’s flight was a reminder that SpaceX’s schedule still has room for someone else’s satellites too. SES gets a finished network built for a narrower set of customers, and Falcon 9 gets one more line on an already long resume.

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Tesla gives the Roadster an official “Go for launch” demonstration date

Tesla teased an October 1 Roadster reveal, reviving years of delayed SpaceX thruster hover promises.

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Concept rendering of a Tesla Roadster with SpaceX Package via Grok
Concept rendering of a Tesla Roadster with SpaceX Package via Grok

Tesla teased an October 1 event date for its next generation Roadster, posting an image on X Saturday that shows the car lit up like it is sitting on a launch pad, with the date “10.01” stamped across the bottom and the caption “Go for launch.” A countdown clock on Tesla’s Roadster order page now points to the same date, which falls on a Thursday. The company has not said where the event will happen or whether it will be streamed at the moment. Stay with us @Teslarati for live updates.


Tesla has since sent formal invitations to reservation holders confirming the event will take place in Waco, Texas, about 90 minutes north of its Austin headquarters, based on a digital ticket shared on X by Sawyer Merritt. Tesla did not name the exact venue, though Waco sits close to SpaceX’s McGregor, Texas, rocket test site, previously reported as the planned location for a Roadster thruster demonstration. The invite sets the reveal for 8:30 p.m. Eastern on October 1, requires RSVPs by midnight on September 16, and limits entry to guests 21 and older. Invitations are non-transferable.

The tease follows nine years of a project defined by unimaginable specs along with slipped dates. Musk first showed the second generation Roadster in November 2017 as a surprise reveal at the end of the Tesla Semi event, promising a 0 to 60 mph time under two seconds, a top speed above 250 mph, 620 miles of range from a 200 kWh battery, and production starting in 2020. At last November’s shareholder meeting, Musk set an April 1 demo date and joked the choice gave him “deniability” if it slipped again, which it did, moving first to late April, then to “a month or so,” then to August.

Tesla Roadster SpaceX Package’s 1.1-second 0-60 mph launch visualized in concept video

Whatever Tesla shows on October 1 is expected to center on the SpaceX developed thruster package Musk has described since 2018. Internally code named A71, a nod to the Lockheed SR-71 Blackbird, the system reportedly uses cold gas thrusters fed by a composite overwrapped pressure vessel, the same tank design SpaceX uses on Falcon 9. Musk has said a thruster equipped Roadster could hit 60 mph in about 1.1 seconds under roughly 2.75 g of launch force, well past the 1.9 second figure quoted for the standard car. That version reportedly will not be street legal and has reportedly been discussed as a limited run sold through a track only program.

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The standard Roadster is still expected to carry the original $200,000 base price and $250,000 Founders Series tier, both set when Tesla opened $50,000 and $250,000 reservations in 2017. Tesla VP of Vehicle Engineering Lars Moravy has confirmed production will happen at Gigafactory Texas, with Musk targeting 2027 or 2028, 12 to 18 months after whatever the company demonstrates next month.

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Tesla plans big safety improvements for Full Self-Driving v15

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Credit: Tesla

Tesla is planning to roll out some pretty significant safety and accident avoidance features with Full Self-Driving version 15, which will be the next major FSD deployment from the company.

Tesla AI lead Ashok Elluswamy used a near-miss this week to preview what the company says is the next leap in Full Self-Driving.

In response to a driver whose car had swerved away from another vehicle pulling out of a parking lot, Elluswamy wrote that he was glad the owner was safe and that “even earlier prediction of hazards, even faster reaction time and overall significantly better safety and collision avoidance” would arrive with FSD v15.

The comment landed as Tesla continues to treat software as the primary safety upgrade path. v15 is described internally as a larger architectural step, with a much bigger neural network and tighter coupling between prediction and control.

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The company has already begun using early v15 software in some robotaxi operations while rolling out safety features such as Automatic Collision Evasion into current customer cars, allowing the driving stack to intervene even when the driver is in manual control.

Tesla is rolling out a new FSD version with a massive safety addition

Tesla’s published telemetry is the backbone of its safety argument. In recent North American Vehicle Safety Report data, vehicles with FSD (Supervised) engaged traveled roughly 5.1 million to 5.7 million miles between major collisions, defined as airbag-deployment events.

Tesla’s estimate of the U.S. average over the same period is about 699,000 miles per comparable crash. That is the comparison Tesla often frames as roughly seven times fewer major collisions.

A tighter comparison uses the same Tesla fleet. Cars driven manually with active safety features such as automatic emergency braking still recorded a major collision about every 2.1 million miles. Against that baseline, FSD’s advantage shrinks to roughly 2.4 to 2.7 times fewer severe crashes, which independent researchers argue is the more apples-to-apples figure.

European data released in 2026 pointed in the same direction: Tesla reported FSD as 3.5 times safer than manual driving in the Netherlands and 4.1 times fewer collisions than manually driven Teslas with active safety across more than 100 million kilometers in five approved countries.

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Those numbers do not settle every debate. NHTSA’s Standing General Order still shows Tesla accounting for the large majority of U.S. Level 2 driver-assist crash reports, in part because the fleet logs far more assisted miles than rivals. Critics also note that Tesla’s “U.S. average” mixes crash definitions and driving mix.

Even so, Tesla’s own same-car comparisons, plus lower rates of automatic emergency braking and harsh maneuvers when FSD is engaged, are the evidence Elluswamy is pointing to when he says v15 will push prediction and collision avoidance further. The claim is not that software already eliminates risk. It is that each major version is meant to widen the gap between the system and an unaided human driver.

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