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SpaceX's next launch ready to go just weeks after in-flight engine failure

SpaceX is just a week away from its seventh launch of the year, set to lift off just weeks after the company suffered its first in-flight engine failure since 2012. (Richard Angle)

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Just weeks after SpaceX suffered its first in-flight rocket engine failure since 2012, the company has scheduled its next launch on April 16th.

Set to lift off no earlier than (NET) 5:31 pm EDT (21:31 UTC) from NASA Kennedy Space Center (KSC) Launch Complex 39A (Pad 39A), the mission will be SpaceX’s seventh dedicated launch of 60 Starlink satellites. Known as Starlink-6 in reference to the sixth launch of finalized Starlink v1.0 spacecraft, a successful mission could leave SpaceX with some ~410 operational satellites in orbit – significantly more than twice as big as the next largest constellation.

More importantly, Starlink-6 will mark a sort of return-to-flight for Falcon 9 after booster B1048 suffered an in-flight engine failure and missed its landing attempt on March 18th. While the booster was able to sacrifice itself to ensure that the overall Starlink-5 mission was a success, any in-flight failure is still a significant event in aerospace. To that end, very little is known about the Starlink-5 anomaly, aside from announcements that both NASA and the US Air Force will be paying close attention to the results of SpaceX’s internal investigation. Starlink-6’s imminent launch is now the latest piece of that puzzle, shedding some welcome light on the situation.

Just weeks after Falcon 9 B1048 suffered SpaceX’s first in-flight engine failure in almost eight years, the company is ready for its next launch. (Richard Angle)

Unsurprisingly, an in-flight Falcon 9 engine failure more than piqued the curiosities of high-profile SpaceX customers like NASA and the US Air Force (and Space Force), both of which have some of the company’s most important launches ever scheduled within the next few months. Most notably, NASA noted on March 25th that the space agency and SpaceX “are holding the current mid-to-late May [target for Crew Dragon’s inaugural astronaut launch] and [will] adjust the date based on review of the [engine failure] data, if appropriate.”

At time of comment, a few aspects of the unfortunate Starlink-5 engine failure were already positioned in SpaceX’s favor. Critically, it was the first time that a flight-proven Falcon 9 booster launched on its fifth orbital-class mission, meaning that the very same booster – B1048 – had already launched four times prior. In aerospace parlance, the mission thus served as a pathfinder for SpaceX’s reusable rocketry technology, venturing into new territory. Since it began internal Starlink launches, SpaceX has used those opportunities to take its most recent reusability leaps without risking customer payloads in the process.

SpaceX completed its first Starlink launch on May 23rd, flying B1049 for the third time. SpaceX's next Starlink launch will very likely mark the first time a booster has flown four orbital-class missions. (SpaceX)
Assigned to SpaceX’s Starlink v0.9 mission, Falcon 9 B1049 became the first booster to launch and land four times in May 2019. (SpaceX)
Marking the second use of a flight-proven payload fairing and first time booster attempted to launch and land for the fifth time, B1048 also tested the limits during a Starlink mission. (Richard Angle)

At least for now, neither NASA or the USAF have plans to fly their most valuable payloads on flight-proven Falcon boosters. While that may change over the next several years, it means that SpaceX’s Starlink-5 anomaly and missions like Crew Dragon Demo-2 and GPS III SV03 – both set to fly on new boosters – share much less commonality. Of course, this assumes that B1048’s March 18th engine failure is directly related to the booster’s exceptionally flight-proven nature. Were SpaceX’s investigation to conclude that the fault had nothing to do with multi-launch wear and tear, it would likely ground Falcon 9 and Falcon Heavy indefinitely.

Despite a relatively hard landing after its third launch, Falcon 9 booster B1051 is scheduled to fly its fourth mission – Starlink-6 – just 79 days later. (Richard Angle)

Instead, SpaceX – knowing full-well the potential consequences of two consecutive in-flight failures – has decided to attempt another orbital-class Starlink launch and booster landing less than a month after Starlink-5. To be clear, while SpaceX could choose to throw caution to the wind on an internal launch, it’s doubtful that it would haphazardly take such a substantial risk. Instead, Starlink-6’s April 16th launch date strongly suggests that SpaceX is already reasonably confident that it’s both determined the likely culprit of last month’s engine failure and identified ways to prevent its reoccurrence.

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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Cybertruck

Tesla Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Elon Musk

Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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Elon Musk

SpaceX has solved Starship’s biggest challenge, Elon Musk says

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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