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SpaceX's latest reusable rocket booster returns to port to prepare for next launch

Falcon 9 B1059 returned to Port Canaveral on December 7th, two days after successfully launching Cargo Dragon on its way to the ISS. (Teslarati - Richard Angle)

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The first new Falcon 9 booster SpaceX has debuted in almost half a year safely returned to port after a successful first launch and landing, setting the reusable rocket up to fly again in the near future.

On December 5th, after a brief 24-hour weather-related delay, new Falcon 9 booster B1059 lifted off on its first mission, successfully sending flight-proven Cargo Dragon capsule C106 to orbit for the third time before the rocket slowed itself down and landed on drone ship Of Course I Still Love You (OCISLY).

Over the next three or so days, the SpaceX spacecraft gradually boosted and tweaked its orbit to rendezvous with the International Space Station (ISS) and ultimately began its ISS approach and berthing maneuvers on December 8th. A few hours after that, ISS astronauts successfully ‘caught’ Dragon with the station’s massive robotic arm and gently berthed the spacecraft at an open port.

Approximately three days after heading to orbit atop Falcon 9 booster B1059, Cargo Dragon C106 successfully docked with the International Space Station (ISS) for the third time. (NASA)

Less than a day before Dragon arrived at the ISS, effectively completing the majority of its CRS-19 resupply mission, the Falcon 9 booster that launched the spacecraft wrapped up a successful launch debut by returning to a different kind of port. Falcon 9 B1059 returned to Port Canaveral aboard drone ship OCISLY on the morning of December 7th and was quickly released from SpaceX’s robotic Octagrabber robot and lifted onto dry land.

SpaceX’s 13th successful Falcon booster recovery of 2019, B1059’s return to port also marked the first flight of a new Falcon booster since June 25th – almost half a year prior. By the numbers, B1059 was subjected to a relatively gentle atmospheric reentry prior to landing aboard OCISLY, meaning that it should be easier for SpaceX technicians and engineers to recertify the rocket and turn it around for its next launch.

Depending on where SpaceX and NASA stand, the booster’s second launch could happen anywhere from 2-4 months from now. Given that NASA currently allows SpaceX to fly reused boosters on NASA missions only if those boosters have exclusively flown NASA missions in the past, B1059 could end up supporting CRS-20, SpaceX’s next and last Cargo Dragon (Dragon 1) mission. CRS-20 is scheduled to launch no earlier than (NET) March 2020 and will be followed by the launch debut of Crew Dragon’s Cargo variant as soon as August 2020, another possibility for B1059’s second flight.

An overview of the expected modifications needed to turn a Crew Dragon into a Cargo Dragon 2. (NASA OIG)

However, if SpaceX follows in the footsteps of CRS-19 and instead prioritizes rapid customer launches over saving a given gently-used booster for another NASA mission, B1059 could be a prime candidate for an extremely rapid turnaround, perhaps supporting an internal SpaceX Starlink launch or any number of other customer satellite launches in early 2020. On the other hand, it’s possible that B1059 suffered an unusually damaging reentry for unknown reasons, although it’s hard to judge from photos and a layperson perspective alone.

From a few angles, it almost appears as if B1059’s white paint was completely burned or scoured off in places, leaving a distinct transition between the edge of remaining paint and the booster’s distinctly metallic-looking skin underneath it. Falcon 9’s main structure is almost entirely built out of a high-performance aluminum-lithium alloy and sealed (and partially shielded) with a multilayer temperature and corrosion-resistant coating. If B1059’s tank coating was indeed partially burned off during reentry, SpaceX will almost certainly have to perform uniquely detailed inspections to verify the structural integrity of its propellant tanks, perhaps preventing a rapid (record-breaking) turnaround.

Falcon 9 B1059 bares apparent battle scars after its first atmospheric reentry and landing. (Richard Angle)

Either way, Falcon 9 B1059 was quickly lifted off of OCISLY and technicians even managed to retract all four of the new booster’s deployable landing legs, a great sign that SpaceX is confident that the booster is in fine shape. With the addition of B1059, SpaceX’s fleet of flight-proven, flightworthy Falcon 9 boosters is now eight strong – nine if Crew Dragon’s unflown Demo-2 booster is included. That fleet will continue to grow as SpaceX gradually introduces new boosters for increasingly rare military and NASA missions.

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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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Google just picked SpaceX for its first step into orbital AI

Google will launch its first Project Suncatcher AI satellite on SpaceX’s Transporter-18 rideshare next week.

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Google is about to put its own AI chips into orbit for the first time, and it is paying SpaceX to get them there.

The company said Thursday that the first in-orbit test of Project Suncatcher, its research effort to find out whether space can host large-scale AI computing, will fly next week on SpaceX’s Transporter-18 rideshare mission.

The satellite, called MVP, is about the size of a refrigerator and carries four of Google’s Tensor Processing Units, the same chips Google runs in its ground data centers. Google originally planned to launch two custom satellites in 2027, but chose to move faster by integrating its chips into a satellite.

MVP’s solar panels supply about one kilowatt of power, and Google will run Gemini models on the TPUs only in bursts of roughly 15 minutes before the chips shut down so the radiators can shed heat. In a blog post, Google said its Trillium TPUs survived vibration testing that mimicked sustained launch loads of up to 10g, with individual components seeing 50 to 100g, and handled a radiation dose greater than a five year mission would deliver.

SpaceX and Google mull massive partnership on Musk’s orbital data dream: report

Next week’s flight, slated for October 1, follows a relationship that became public in May, when Teslarati reported that Google was in talks with SpaceX for a launch deal tied to orbital data centers. Google also holds a stake of roughly 6% in SpaceX.

The two companies are chasing the same idea from very different starting points. SpaceX’s own orbital compute program is built around the AI1 satellite, a roughly 70 meter structure derived from Starlink V3 hardware that is designed for 150 kW of peak compute, about 150 times the power MVP will draw. Elon Musk has brushed off concerns about crowding orbit with those satellites, and SpaceX is building its Gigasat factory in Bastrop, Texas, to produce them, targeting an annualized rate of about 1 GW of space compute by the end of 2027.

Musk also posted on X on Thursday that “the amount of compute in space will obviously round up to 100% of all compute.”

Google has been more cautious in public. Its research estimates that launch prices need to fall below about $200 per kilogram before an orbital data center can compete with a ground facility on energy cost, a threshold the company believes could be reached around the mid 2030s. The Suncatcher team has said it expects the effort to remain a project rather than a product for years, which leaves the first real test of its hardware riding on a rocket from the company with the most aggressive timeline in the field.

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Tesla Cybercab gets initial tie-in to localized, in-house cathode plant

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Credit: Tesla

Tesla has taken another concrete step toward owning its battery supply chain, and it’s doing so with what is perhaps the most important vehicle in its short-but-storied history.

On September 23, Tesla announced that it has officially built the first Cybercab with cathode material produced in-house at the company’s first cathode plant in the U.S., and the first in the U.S. overall.

Active cathode material is the most expensive piece of a lithium-ion battery cell, and it often accounts for more than a third of cell cost. For years, the industry sourced a majority of it from Asia, but Tesla’s decision to make it in the United States bodes well for the Cybercab project. This is the latest chapter in Tesla’s vertical integration strategy, which began in public at Battery Day in 2020.

At the Battery Day Event, Elon Musk said the company would build a North American cathode plant and overhaul the process to cut costs and waste, while also making some of the most powerful and long-lasting cells in the industry.

The Austin facility took years to appear. Tesla filed permits for “Project Cathode” in 2022 on land near Giga Texas. By mid-2022, the building frame was up and Tesla later invested hundreds of millions of dollars as part of a larger expansion of the Giga Texas plant. The company stated it was operating the first large-scale cathode production facility in North America to supplement 4680 cell production.

One month later, that material reached a finished Cybercab.

The timing of this breakthrough is monumental for the Cybercab program. As Tesla officially launched the first Cybercab rides to the public earlier this month, production of the ride-hailing-geared vehicle is moving forward on the planned S-curve that CEO Elon Musk told everyone to expect.

Nevertheless, packs of Cybercab units have been spotted throughout the United States, in an effort to potentially activate the fleet as soon as the company gains regulatory approval in various geographic areas.

On top of that, Tesla owning the cathode step and pairing it with its own in-house lithium from the Gulf Coast refinery shortens the supply chain that once stretched thousands of miles and subjects every pack to fewer external price shocks and geopolitical risks.

Tesla is not yet independent of all of its foreign suppliers, as some precursor metals come from mines and chemical plants. But the first in-house cathode Cybercab shows the company is closing the most expensive and most concentrated gap in its battery production efforts. For a vehicle like Cybercab to operate at a high utilization within the Robotaxi network, that control over cost is so crucial.

It is arguably as important as the software that drives it.

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Tesla leaks Semi customers ahead of handover event

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Credit: Tesla

Tesla is set to inaugurate its dedicated Semi factory in Sparks, Nevada, this evening, but drone footage has already started to show who is expected on the handover stage.

Zanegler, a drone operator who regularly documents Tesla Semi operations in Nevada, filmed a row of new-generation Semi units parked outside of the plant with customer branding applied. The liveries visible in the video include companies like PepsiCo, U.S. Foods, Einride, DHL, WattEV, and others that have committed to utilizing Tesla’s Class 8 electric truck in their fleets.

Several of those company names already sit within Tesla’s public ordering book, including PepsiCo, which has been the program’s primary anchor customer since the first Semi deliveries in December 2022. PepsiCo now runs dozens of Tesla Semi units in daily service, with drivers completing regional routes.

Einride placed a 500-unit order in August, which was, at the time, the largest single Semi commitment. First deployments of their Semi units are planned for this month and will eventually span across California, Texas, New Jersey, Illinois, and Georgia. Meanwhile, IMC Logistics announced a 50-truck California order this week.

Tesla Semi lands the biggest electric truck deal in U.S. history

Other names, like LTS, OK Produce, and HMD, have not been widely confirmed as firm buyers, but their presence on the lot is perhaps the clearest signal that Tesla intends to expand on that list this evening at the event.

Tesla first unveiled the Semi back in 2017 with a 2019 production target.

Limited pilot builds reached PepsiCo in late 2022, and high-volume production began at the new 1.7-million-square-foot plant that sits logically positioned next to Tesla’s Gigafactory Nevada. Tesla Semi program director Dan Priestley has said that Tesla expects to build “many thousands” of Semi units this year, but as with every Tesla release, there have been set expectations of an S-curve ramp.

Outside estimates still put 2026 deliveries in the 5,000-to-15,000 range, but it will ultimately depend on Tesla’s readiness to put those units out, as well as how smoothly production is moving internally.

Tesla’s Semi Rollout event is set to start tonight at the Sparks factory, and it will be livestreamed on X starting at 6 p.m. PDT / 9 p.m. ET.

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