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SpaceX's next Starlink launch to mark biggest rocket reusability milestone yet [webcast]

Falcon 9 booster B1048 is just hours hours away from attempting to cross SpaceX's biggest reusability milestone yet. (Pauline Acalin, SpaceX, Tom Cross, Richard Angle)

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If everything goes as planned, SpaceX’s next 60-satellite Starlink launch will soon push the Falcon rocket family to the halfway point of its ambitious reusability design goals.

SpaceX has scheduled its sixth launch of 60 Starlink satellites no earlier than (NET) 9:42 am EDT (13:42 UTC) March 14th. Known as Starlink L6 or Starlink V1 L5 (referring to the fifth batch of upgraded v1.0 satellites), the Starlink mission will be the SpaceX’s fourth this year – a cadence that would enable up to 21 Starlink launches in 2020 alone. In other words, a successful launch this weekend would put SpaceX firmly on track to realize the repeated guidance that it would attempt 20-24 Starlink missions this year.

Given that SpaceX’s annual record stands at 21 launches and that the company has many additional non-Starlink launches planned for 2020, it’s always been clear that rocket reusability would be essential to even begin to approach the launch rates Starlink demands. Doing so without severely impacting customer missions – almost certainly an unacceptable tradeoff for SpaceX – is even more of a challenge. Thankfully, with its very next launch, SpaceX is about to push the rocket reusability envelope yet again, hopefully proving that the Falcon family is halfway to realizing its design goals.

Record-breaking Falcon 9 booster B1048.4 is now on track to break yet another record for reusable SpaceX rockets. (Richard Angle)

SpaceX’s final iteration of the Falcon launch vehicle – known as its Block 5 upgrade – flew for the first time in May 2018 and has performed another 27 missions in 22 months since. When it debuted, SpaceX CEO Elon Musk spoke in depth about the Block 5 upgrade and the significant changes it introduced, stating that it primarily focused on improving reliability and reusability. Notably, every single Falcon 9 Block 5 rocket produced from then on would be virtually identical to the select few boosters destined to launch astronauts, meaning that all future SpaceX launches would directly benefit from the changes NASA required.

Since July 2018, all SpaceX launches have featured rockets all but identical to those that will soon launch astronauts. (SpaceX)

However, arguably the biggest public focus of Block 5 upgrade would be the upgrades it brought for SpaceX’s reusable rocketry program, with Musk describing it as a cumulative product of half a decade spent attempting to land rocket boosters. The big claim: Falcon Block 5 boosters would theoretically be capable of at least ten launches apiece with minimal to no repairs in between. After reaching 10-launch milestones, Musk further noted that boosters could potentially use periodical overhauls – much like modern aircraft – to achieve 100 or more launches apiece before retirement.

Eleven months after SpaceX launched and landed the same rocket for the third time, Falcon 9 booster B1048 became the first to complete four launches and landings, placing the first 60 Starlink v1.0 satellites in orbit in November 2019. Less than two months later, Falcon 9 B1049 matched its predecessor’s record, becoming the second booster to launch four times.

Falcon 9 B1048.4 returned to Port Canaveral aboard drone ship OCISLY on November 15th. (Richard Angle)
Falcon 9 B1049 returned to port on January 9th after launching Starlink V1 L2. (Richard Angle)

Now, according to Next Spaceflight, pathfinder Falcon 9 booster B1048 is scheduled to launch for the fifth time in support of Starlink L6 – a bit less than four months after it became the first SpaceX rocket to cross the fourth-flight milestone. Just days ago, SpaceX President and COO Gwynne Shotwell revealed that Falcon boosters might never need to fly more than ten times. Given that Falcon 9 Block 5 boosters were first and foremost designed to launch no less than ten times each, B1048 is now on the brink of reaching the halfway point of one SpaceX’s most ambitious Block 5 design goals.

If B1048 (and B1049 shortly after that) can prove that Falcon boosters can successfully launch five times, it’s hard to imagine any technical showstoppers that could prevent SpaceX from achieving its self-imposed ten-flight milestone. With SpaceX likely to attempt anywhere from 10-20 more Starlink launches this year, there will be no shortage of opportunities for Falcon 9 to continue pushing the envelope of reusability.

Tune in around 15 minutes before liftoff to catch SpaceX’s Starlink L6 launch live this Saturday, pending a successful Falcon 9 static fire test later today.

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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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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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