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SpaceX military launch cleared for historic rocket landing attempt

A Falcon 9 booster - likely B1060 - fired up its nine Merlin 1D engines during a routine Texas acceptance test on February 13th. (SpaceX)

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SpaceX officially has permission to perform a Falcon 9 booster recovery after its next launch for the US Air Force, now guaranteed to be the first time a rocket booster attempts to land during an operational launch for the US military.

Alongside their booster landing attempt confirmation, the USAF Space and Missile Systems Center (SMC) also posted the first official SpaceX video of a rocket acceptance test released in almost 2.5 years, a test it says was completed just days after the GPS satellite it’s scheduled to launch arrived in Florida. The very same Falcon 9 booster was shown off in unprecedented detail just last month and now SMC says that SpaceX fired up the rocket at its McGregor, Texas development facilities for a routine static fire on February 13th. The company is currently scheduled to launch its second USAF GPS III satellite – Space Vehicle 03 (SV03) – no earlier than 7am EDT (11:00 UTC), April 29th, a target set just days ago.

With the spacecraft in Florida and factory-fresh Falcon 9 booster successfully proofed, all that remains is for SpaceX to test and deliver the mission’s Falcon upper stage and payload fairing (if it hasn’t already). After the booster – believed to be B1060 – is inspected and its tanks are cleaned, it can also be packaged and transported by road the rest of the way to SpaceX’s Florida launch facilities, setting the company up for the critical mission and historic landing attempt.

While SpaceX has technically already landed Falcon 9 and Falcon Heavy boosters after its NROL-76 and STP-2 launches for the NRO and USAF, the company only officially began operational military launches once its Falcon 9 rocket was fully certified. STP-2, for example, was effectively high-stakes make-work designed to help the USAF fully certify SpaceX’s brand new Falcon Heavy rocket to launch expensive – verging on irreplaceable – military satellites.

Its first truly operational US military launch occurred in December 2018, when Falcon 9 booster B1054 was intentionally expended in support the USAF’s inaugural GPS III launch, successfully placing the first of 10 (or 32) planned upgraded navigation satellites into orbit. It’s believed that the USAF required such extreme safety margins (extra propellant and performance) that SpaceX couldn’t even attempt booster or fairing recovery. This made B1054 the first (and hopefully only) Falcon 9 Block 5 booster to launch without even the basic hardpoints needed to attach landing legs.

Falcon 9 lifts off with the US Air Force’s first ~$500M GPS III spacecraft, December 2018. (SpaceX)

Effectively confirming that B1054’s demise was was a contrivance and by no means a technical necessity, the SMC announced on February 20th that SpaceX’s GPS III SV03 mission is officially “the first time a booster is planned to land on a drone ship during a NSS [National Security Space] launch.” Effectively identical to B1054 aside from the addition of grid fins and landing legs, this means that Falcon 9 booster B1060 will be able to attempt a landing aboard a SpaceX drone ship shortly after launch.

The GPS III SV03 satellite is seen in September 2019 as technicians prepare it for transport. (Lockheed Martin)

Just like GPS III SV01 satellite launched by SpaceX in December 2018 and the GPS III SV02 satellite launched United Launch Alliance (ULA) launched in August 2019, GPS III SV03 is a more than $500 million spacecraft designed to upgrade the US GPS navigation constellation. SpaceX has already won five (of five) competitively-awarded GPS III launch contracts thanks to its Falcon 9 rocket’s exceptionally competitive pricing, meaning that there is an excellent chance the company will win many more in the near future.

GPS III SV03 is one of 10 “Block IIIA” satellites to be launched between 2018 and 2026 and will be followed by another 22 “Block IIIF” satellites to be built by Lockheed Martin for ~$330M apiece. All 26 unassigned spacecraft will need launches of their own between now and the mid-2030s, worth anywhere from $1-2.5B to SpaceX if the company performs well on all five of its first contracts and continues to crush competitor ULA on launch costs.

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Falcon Heavy Flight 3 made use of both flight-proven side boosters and a new center core. Note the scorched landing legs and sooty exteriors. (SpaceX)
Falcon Heavy launched the USAF STP-2 mission with two flight-proven side boosters, launched barely 74 days after their first flights. Note the scorched landing legs and sooty exteriors. (NASA – Kim Shiflett)
USAF photographer James Rainier's remote camera captured this spectacular view of Falcon Heavy Block 5 side boosters B1052 and B1053 returning to SpaceX Landing Zones 1 and 2. (USAF - James Rainier)
Through Falcon Heavy STP-2, the Air Force has thus already directly supported an incredibly ambitious instance of orbital-class booster reuse. (USAF – James Rainier)

With the USAF already demonstrably interested in supporting Falcon booster reusability and now open to SpaceX recovering Falcon 9 boosters after moderately-challenging GPS III launches, it’s safe to say that SpaceX’s ultra-competitive pricing is here to stay.

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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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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

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

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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