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SpaceX’s record-breaking Falcon 9 booster returns to port

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SpaceX’s latest record-breaking Falcon 9 booster has returned to port after completing its 13th launch and landing.

Falcon 9 B1060 lifted off for the first time in June 2020 with the US military’s third next-generation GPS III satellite safely cocooned inside a payload fairing. Unlike B1054, which the US Air Force required SpaceX to expend after their first GPS III satellite launch, the military allowed the company to attempt to recover booster B1060. That first successful recovery would unknowingly pave the way for a future of firsts and for an exceptionally productive career.

After GPS III SV03, B1060 occasionally supported commercial launches like Turkey’s Turksat 5A geostationary communications satellite and one of SpaceX’s own Transporter rideshare missions, but the booster has primarily been assigned to Starlink launches. In early 2021, the booster smashed SpaceX’s internal turnaround record and spent just 27 days on the ground between its fourth and fifth launches – halving the 54-day record set by NASA’s Space Shuttle, the only other orbital-class rocket that has ever been repeatedly reused.

B1060 has singlehandedly supported the launch of 550 Starlink satellites weighing more than 150 metric tons (>330,000 lb). Altogether, it’s helped launch more than 640 satellites with a collective weight around 165 tons. After its June 17th launch of Starlink 4-19, it’s also supported more orbital-class launches and landings – 13 – than any other Falcon booster, although Falcon 9 B1051 and B1058 are close behind with 12 launches apiece.

Falcon 9 B1060 rolls out to LC-40 for its inaugural launch. (SpaceX)
B1060’s first successful landing. (SpaceX)
B1060’s 13th landing.

According to senior SpaceX engineers and executives that recently provided exclusive interviews to Aviation Week, the company no longer believes it will need to fly Falcon 9 boosters more than 15 times each, with the implication being that Starship – a next-generation, fully-reusable rocket – will soon begin to take over. Once a Falcon 9 booster (now likely to be B1060) completes its 15th launch, SpaceX intends to take it out of service and perform extensive inspections. If the data gathered is encouraging, it will certify all current and future Falcon boosters for 15 launches each.

It’s unclear if that 15-flight target is a firm cap or if exceptionally productive boosters like B1060, B1051, and B1058 will be allowed to continue pushing the envelope of reuse on future Starlink missions. At their current rate of launch, there’s a good chance that all three could complete 15 launches before the end of 2022. Slightly older and more tempermental, booster B1049 will reportedly be expended after its eleventh launch sometime later this year. If SpaceX’s plan is to full remove boosters from service after Flight 15, the company’s fleet of regularly flying boosters could plummet from 12 to 8 around around the end of 2022 or early 2023.

Following B1060’s June 21st port return, Falcon 9 booster B1061 sailed into port on SpaceX’s other East Coast drone ship on June 22nd after SpaceX launched Starlink 4-19 and Globalstar FM15 (B1061’s latest mission) 36 hours apart the weekend prior. That kind of rapid-fire cadence will likely become a regular occurrence in the second half of 2022 if SpaceX continues to launch an average of once per week, and the company is showing no signs of slowing.

(Richard Angle)
(Richard Angle)
Support ship Bob returns with three Falcon fairing halves. (Richard Angle)

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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