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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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Tesla Optimus Gen 3 shows off a cleaner, factory-ready design in new app discovery

Renders hidden inside Tesla’s Android app show Optimus Gen 3’s design before any official reveal.

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla may have accidentally given a first look at its newest Optimus Gen 3 humanoid robot when photos were found in the Tesla smartphone app.

Design files tucked inside a recent Android version of the Tesla app appear to show the third generation humanoid robot next to the older Gen 2.5 prototype. The assets were extracted from the app package by Tesla community member @wholemars, who posted the renders on X late Tuesday night before deleting them. The Tesla Newswire reshared the side by side comparison on Wednesday, and the images have circulated widely since.

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

The files are labeled “gen3” and were built as models for Tesla app’s own interface, as validated directly by Grok to be official.

The comparison shows a robot that looks built for a factory line rather than a lab bench. Gen 2.5’s exposed mechanical linkages and gold plating on the knees and shins are gone. In their place, Gen 3 uses matte black fairings on the lower legs, paired with a more contoured champagne gold body. Flexible covers now seal the joint where the torso meets the upper thighs, keeping bearings and moving parts sealed from debris and unnecessary contact.

The body panels fit more tightly, and the hands, which Tesla has said carry 22 degrees of freedom, look far more refined than those on earlier units.

This most recent leak fills a gap Tesla has left open for most of the year. Elon Musk said on March 31 that Optimus 3 was walking around but needed “some finishing touches” before it could be shown, a delay Teslarati covered when Tesla missed its first quarter reveal target. Musk later said Tesla would hold the design back until closer to production, partly to keep competitors from copying it. No reveal date has been announced.

The app itself has been preparing for Optimus for months. In July, code in the Tesla app pointed to a dedicated robot phone key, a consent screen for collecting video and spatial data while Optimus works inside a home, and an alert system for low battery and mechanical faults. Finished 3D models of Gen 3 suggest the interface owners will eventually use is moving past placeholder code toward something Tesla intends to ship.

Manufacturing is moving in parallel. Tesla tore out the original Model S and Model X lines at Fremont this summer to make room for Optimus production, with a planned capacity of one million robots a year. At Giga Texas, the steel frame of a dedicated Optimus factory is nearing completion ahead of a targeted 2027 start, with Musk pointing to an eventual output of 10 million units annually.

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Tesla Semi lands the biggest electric truck deal in U.S. history

Tesla leads a record 2,500 truck order, but not every truck will be a Semi.

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Tesla has landed the largest electric truck order in U.S. history. ZET SCALE, a new alliance of shippers and carriers, named Tesla its primary manufacturer on Tuesday for an initial order of 2,500 electric Class 8 trucks. The deal alone would nearly double the number of electric heavy trucks operating in the country.

According to the press release from Catalyst Mobility, the nonprofit formerly known as CALSTART, Kenworth, RIDE and Volvo were also selected as secondary manufacturers that carriers can pick if their operations call for it. No split between the four brands has been published, so the exact number of Semis in the order is not yet known.

Tesla won the top slot through a competitive request for proposals. The alliance, which Catalyst Mobility runs with the Smart Freight Centre, scored bidders on price, range, charging capability and production capacity. Pooling freight demand from founding shippers, including Microsoft and PepsiCo, let every truck maker bid lower than it would for a single fleet. “The Tesla Semi is designed for lower cost per mile operations than diesel,” said Dan Priestley, director of the Tesla Semi program, as noted in the press release.

The financing is built to pull in carriers who have avoided electric trucks. ZET Financial is issuing the purchase order for all 2,500 units and will place them with fleets through a fair market value lease. The trucks will be deployed over the next few years across 10 freight hubs in Los Angeles, Stockton, Bakersfield, Seattle and Tacoma, Houston, Dallas, San Antonio, Chicago, Atlanta, and the Newark and New York area. ZET SCALE says the first order is only the opening round, with a longer term goal of 10,000 trucks or more.

Even if Tesla ends up with only a majority share, it would still be the biggest Semi deal to date. Einride’s 500 unit order in August was the previous record, and WattEV’s 370 truck order in May was the largest California deal at the time. Einride’s CEO has since said he expects all 500 trucks delivered by the end of 2027.

The announcement lands two days before Tesla formally inaugurates its Semi factory in Nevada on September 24. The 1.7 million square foot plant sits next to Gigafactory Nevada’s 4680 cell lines and is designed for 50,000 trucks a year.

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Tesla integrates Grok Bot into its vehicles for the ultimate personal assistant

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Credit: Grok

Tesla has expanded Grok from an in-car chatbot into a hands-free work assistant. On September 22, Tesla officially launched Grok Bot capability, confirming that drivers can now manage email, calendars, files, chats, and tasks by voice and then hand more ambitious errands to the AI-fueled productivity cheat code.

Grok itself is built by xAI. The new car features split into two layers: Connectors link Grok to outside accounts. Grok Bot, currently limited to SuperGrok Heavy subscribers, can complete multi-step tasks such as placing a usual coffee order, booking a reservation, or scheduling an appointment. It truly puts the driver in a nearly complete hands-free driving and productivity setting, with ironically the only task truly requiring your hands being to touch the “Start Self-Driving” button.

We were granted access to Grok Bot’s Tesla integration a few weeks back, and we’ve been able to do a handful of things with it. On a handful of occasions, we’ve used it to order food and have it ready for pickup slightly later into the evening; we’ve managed to pick up groceries after a day of errands with Grok Bot, and outside of the car, it’s helped with budgeting and even my fantasy football draft.

Tesla shows another way to utilize it: in their demo, a driver says “Hey Grok,” asks the assistant to check an inbox, and hears that a message concerns a weekend reservation. Grok then scans the calendar, reports no conflicts, and confirms the Tahoe trip is clear. It can also add check-in details to a road-trip itinerary. The point is not novelty chat. It is keeping eyes on the road, or on Full Self-Driving, while the car handles the paperwork of a trip:

This Grok rollout is not a gadget add-on as much as it is Tesla’s thesis in software form: the car should stop being a machine you operate and start being a room you occupy.

Connectors and Grok Bot treat the cabin as an office that happens to move, and that has truly been Tesla’s intention for years now. The car has slowly become an extension of a home more than a vehicle. Inbox, calendar, groceries, takeout, and reservations become voice work, not dashboard chores that you need to do before you get in your car.

Responsibility shifts from the driver to the stack, and as many Tesla owners rely on FSD for travel, Grok Bot now handles the monotony of dinner reservations or appointments.

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