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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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Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says

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Credit: United Airlines

United Airlines CEO Scott Kirby said that SpaceX’s Starlink satellite internet is its leading competitive advantage in the U.S. airline industry. However, in recent comments, while he described the service as “the biggest competitive advantage” the carrier currently holds, he also acknowledged that the edge is temporary.

“…everybody eventually is going to have high-speed low earth orbit internet connectivity. It’s going to be a must-have. We are going to have a few years of being the only airline that has it at scale, and that’s our mission,” Kirby said. Until everyone has it, United aims to capitalize on its head start by converting trial users into long-term loyal customers.

United has moved faster than its rivals on Starlink installations. As of mid-to-late October 2026, the system was on roughly 43 percent of its fleet, with plans to reach 61 percent by year-end, 87 percent by June 2027, and full fleet coverage by the end of next year.

The airline already operates more Starlink-equipped flights than the rest of the U.S. industry combined. Los Angeles International Airport is scheduled to become United’s first 100 percent Starlink hub in the first half of 2027, and the carrier’s app will display the likelihood that any given flight has the service.

Kirby has pointed to early evidence that the offering influences booking decisions. Some passengers loyal to other airlines are already switching flights for Starlink connectivity, something the airline, along with American Airlines, has tried to leverage against competing airlines. Both companies used status-match programs, and some of those customers are pursuing company-specific credit cards, which signals an intent to stay.

Once onboard, these customers encounter the airline’s broader investments in aircraft, larger seat-back screens, oversized bins, connection tools, and a mobile app that Kirby says outperforms competitors. Wi-Fi satisfaction scores on Starlink-equipped planes have been reported to be nearly double those on aircraft with other systems.

Competitors are moving slowly to do the same. Southwest Airlines began installations in 2025 and expects to complete them soon. Delta is pursuing Amazon’s Leo system, while American expects to start Starlink work in early 2027 and has not yet detailed regional-fleet plans. This timeline gap gives United a multi-year window in which it remains the only major U.S. carrier offering Starlink at scale.

Kirby has framed the strategy as pressing that advantage while simultaneously widening gaps in other technology areas so that customers who try United for the Wi-Fi remain for the overall experience.

The approach reflects a calculated bet that superior in-flight connectivity can accelerate share gains and support longer-term financial targets, including a 10 percent pre-tax margin goal.

High-speed internet is particularly valued by premium and business travelers who can work or stream reliably. As low-Earth-orbit service becomes ubiquitous, the temporary nature of the pure connectivity edge means United’s retention will depend on whether its other product and operational improvements keep pace.

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Tesla Cybercab’s unorthodox paint process explained

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Credit: Tesla

Tesla Cybercab skips the traditional paint shop entirely, marking an unorthodox process for coloring the fully autonomous vehicle. However, the decision was a smart one, as it slashed factory costs, floor space utilization, and complexity, since Tesla relied on specialized alloys and in-mold coloring.

Munro Live was given the opportunity to do a factory walkthrough with Tesla Vice President of Vehicle Engineering Lars Moravy, who explained and detailed how Cybercab production at Giga Texas eliminates one of the automotive manufacturing industry’s most expensive and space-hungry elements.

A conventional paint line can cost hundreds of millions of dollars and require a million man-hours to build. Moravy framed the choice around Tesla’s core rule: “Question the requirements: why do you need paint?”

The structural answer lies in material selection. The aluminum alloys used in Cybercab’s front and rear castings do not oxidize and lose strength over time, the way many common automotive aluminum alloys do. Only the side modules, built around hot-stamped boron-steel door rings, receive an anti-corrosion e-coat, or dip coat. Front and rear modules skip coating altogether.

Model Y and Model 3 bodies, by contrast, are fully coated and painted.

Exterior colors come from the plastics shop, which Tesla engineers described as “our paint shop” for the Cybercab. Body panels are produced via reaction injection molding, referred to as RIM. Color is then mixed into a polyurethane resin at the mix head immediately before injection, so the panel emerges already colored with a Class-A surface.

Robots trim overflow to control sink marks and flow lines. The process avoids conventional spray-paint defects like orange peel and paint bleed. Scratches can still be repaired with compatible coatings that behave “basically like paint.” Because color is integral rather than a surface layer, shallow scratches do not expose a contrasting undercoat.

The secret behind Tesla’s Cybercab Gold goes well beyond just the color

Tesla has also explored related approaches, including in-mold lamination and painted films on stamped panels.

The manufacturing payoff is substantial because removing the paint shop, combined with the “unboxed” modular process that builds and tests front, rear, side, and center modules in parallel before a short final assembly, cuts factory floor space per vehicle by about 50 percent.

Final assembly itself uses only about 25 automated stations, far fewer than the typical Model Y line, and the overall line runs at about 78 percent automation, Moravy said. The approach also eliminates volatile organic compound emissions associated with traditional spray painting for these panels and shortens the coloring cycle from hours to minutes.

Cybercab’s paint strategy is clearly less about aesthetics than about systematically deleting capital-intensive, energy-heavy, and space-consuming steps once material science and process design make them unnecessary. It is a concrete example of Tesla applying first-principles questioning to one of the auto industry’s most entrenched factory requirements.

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Tesla has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

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Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

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The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

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