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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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Investor's Corner

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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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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