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SpaceX record-setting booster returns to Port in remarkable condition (photos)

Booster B1049 returned to Port after delivering a batch of 60 Starlink satellites into space. Credit: R. Angle/Teslarati

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SpaceX has successfully recovered its second Falcon 9 in less than a week. Just four days after it launched, booster B1049 returned to sailed into Port Canaveral. The veteran booster is the first to launch and successfully land five times. On June 3, at 9:25 p.m. EDT (0125 GMT on June 4), B1049 took to the skies, delivering another batch of Starlink satellites into orbit.

Now, just three days after a flawless mission, the veteran rocket sailed triumphantly into port. Perched atop SpaceX’s newly remodeled drone ship, Just Read the Instructions (JRTI), B1049’s exterior was visibly more charred after its most recent trip through the atmosphere. This successful landing marks the first mission that JRTI was active in the Atlantic Ocean, as well as the third successful sea recovery in a row for SpaceX.

So far this year, SpaceX has successfully launched nine boosters this year. All but two of them have been recovered—two failed to land on the drone ship. One of those botched attempts was due to some residual cleaning agents trapped inside the engine. That booster, B1048, was SpaceX’s only other booster (so far) to fly five times. 

SpaceX’s Falcon 9 booster B1049 has successfully launched and landed five times. Credit: R. Angle/Teslarati

But it surely won’t be the last. B1051 has already completed four successful missions and could see flight again soon. SpaceX has at least two other launches planned for June, including another Starlink launch and the launch of a GPS satellite for the Air Force. That flight will be on a new booster, B1060, per the Air Force’s request.

As it stands now, government payloads require SpaceX to use a new booster, versus a previously flown one. That was also the case for NASA’s commercial crew program. On May 30, astronauts Bob Behnken and Doug Hurley flew to the International Space Station atop a Falcon 9 rocket. The booster, which returned to Port just a few days ago, what a shiny new booster. However, in a recent development, NASA amended the agreement, saying that SpaceX could use previously flown boosters as well as reuse its Crew Dragon spacecraft.

Currently, SpaceX reuses its cargo version of Dragon, but each upgraded cargo (and Crew) variant can be reused as many as five times. Each booster is currently rated for ten flights, with minimal refurbishments in between.

SpaceX’s fleet of veteran rockets has dwindled a bit, with the loss of B1048 and B1056. Those losses came on the heels of two planned expenditures: B1046 and B1047. B1046was purposefully detonated as part of the company’s In-flight Abort test that occurred in January. That test was a lead up to the Demo-2 mission and proved that SpaceX’s launch escape system worked while B1047 carried the AMOS-17 satellite into orbit and was expended after depositing the satellite into space.

However, the California-based rocket builder should have some new Falcons rolling off the assembly line this summer, which will help support its ambitious Starlink launch manifest. This year, SpaceX has launched six Starlink missions, with at least one more planned for June, possibly two.

To date, SpaceX has launched a total of 482 Starlink satellites, but the company needs between 400-800 satellites on orbit to begin rolling out minimal coverage. To provide the coverage it wants, SpaceX is going to have to keep up the launch pace. And to do so, it will test the reusability factor of its rockets.

So far, we’ve seen two rockets fly five times, but when will B1049 fly a sixth time? How soon will we see a booster reach the 10-flight mark? What sort of refurbishments will it need then? With many more Starlink flights on deck, it will be interesting to see which boosters fly on which missions.

I write about space, science, and future tech.

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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.

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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.

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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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