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SpaceX’s Starlink launch debut to orbit dozens of satellites later this month

Trust me, I do appreciate the irony of using a OneWeb/Arianespace render to illustrate a SpaceX Starlink launch. Nevertheless...(Arianespace)

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SpaceX President and COO Gwynne Shotwell has revealed that the company’s first dedicated Starlink launch is scheduled for May 15th and will involve “dozens” of satellites.

Corroborated by several sources, the actual number of Starlink satellites that will be aboard Falcon 9 is hard to believe given that it is a satellite constellation’s first quasi-operational launch. Suffice it to say, if all spacecraft reach orbit in good health, SpaceX will easily become the operator and owner of one of the top five largest commercial satellite constellations in the world with a single launch. Such an unprecedentedly ambitious first step suggests that the perceived practicality of SpaceX’s Starlink ambitions may need to be entirely reframed going forward.

From 0 to 100

In short, it’s hard to exaggerate just how much of a surprise it is to hear that SpaceX’s very first Starlink launch – aside from two prototypes launched in Feb. 2018 – will attempt to place “dozens” of satellites in orbit. Competitor OneWeb, for example, conducted its first launch in February 2019, placing just six satellites in orbit relative to planned future launches with 20-30. To go from 2(ish) to “dozens” in a single step will break all sorts of industry standards/traditions.

Despite the ~15 months that have passed since that first launch, SpaceX’s Starlink team has really only spent the last 6-9 months in a phase of serious mass-production buildup. As of now, the company has no dedicated satellite factory – space in Hawthorne, CA is far too constrained. Instead, the design, production, and assembly of Starlink satellites is being done in 3-4 separate buildings located throughout the Seattle/Redmond area.

One of SpaceX’s Seattle properties.

SpaceX’s Starlink team has managed to transition almost silently from research and development to serious mass-production (i.e. dozens of satellites) in the space of about half a year. The dozens of spacecraft scheduled to launch on SpaceX’s first dedicated mission – likely weighing 200-300 kg (440-660 lb) each – have also managed to travel from Seattle to Cape Canaveral in the last few months and may now be just a few days away from fairing encapsulation.

To some extent, the first flight-ready batch of “dozens” of satellites are still partial prototypes, likely equivalent to the second round of flight testing mentioned by CEO Elon Musk last year. This group of spacecraft will have no inter-satellite laser (optical) links, a feature that would transform an orbiting Starlink constellation into a vast mesh network. According to FCC filings, the first 75 satellites will be of the partial-prototype variety, followed soon after by the first spacecraft with a more or less finalized design and a full complement of hardware.

If this is just step one…

Meanwhile, Shotwell – speaking at the Satellite 2019 conference – suggested that SpaceX could launch anywhere from two to six dedicated Starlink missions this year, depending on the performance of the first batch. Put a slightly different way, take the “dozens” of satellites she hinted at, multiply that number by 6, and you’ve arrived at the number of spacecraft she believes SpaceX is theoretically capable of producing and delivering in the next 7.5 months.

“Dozens” implies no less than two dozen or a bare minimum of 144 satellites potentially built and launched before the year is out. However, combined with a target orbit of 450 km (280 mi) and a planned drone ship booster recovery more than 620 km (385 mi) downrange, 36, 48, or 60 satellites seem far more likely. Tintin A/B – extremely rough, testbed-like prototypes – were about 400 kg (~900 lb) each.

As an example, SpaceX’s eight Iridium NEXT satellite launches had payloads of more than 10,000 kg (22,000 lb), were launched to an orbit around 630 km (390 mi), and required a upper stage coast and second burn on-orbit. Further, Iridium missions didn’t get the efficiency benefit that Starlink will by launching east along the Earth’s rotational axis. Despite all that, Falcon 9 Block 5 boosters were still able to land less than 250 km (155 mi) downrange after Iridium launches. Crew Dragon’s recent launch debut saw Falcon 9 place the >13,000 kg (28,700 lb) payload into a 200 km (125 mi) orbit with a drone ship landing less than 500 km (310 mi) downrange, much of which was margin to satisfy safety requirements.

Starlink-1’s target orbit is thus a third lower than Iridium NEXT, while its drone ship will be stationed more than 2.5 times further downrange. Combined, SpaceX’s first Starlink payload will likely weigh significantly more than ~13,000 kg and may end up being the heaviest payload the company has yet to launch.

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An Arianespace render of a OneWeb launch offers the best unofficial look yet at what SpaceX’s first Starlink launch might look like. (Ariane)

Assuming a payload mass of ~14,000 kg (~31,000 lb) at launch, a worst-case scenario with ~400 kg spacecraft and a 2000 kg dispenser would translate to 30 Starlink satellites. Cut their mass to 300 kg and the dispenser to 1000 kg and that rises to ~45 satellites. Drop even further to 200 kg apiece and a single recoverable Falcon 9 launch could place >60 satellites in orbit.

Of course, this entirely ignores the elephant in the room: the usable volume of SpaceX’s standard Falcon payload fairing. It’s unclear how SpaceX would fit 24 – let alone 60 – high-performance satellites into said fairing without severely constraining their design and capabilities. SpaceX’s solution to this problem will effectively remain unanswered until launch, assuming the company is willing to provide some sort of press release and/or offer a live view of spacecraft deployment on their webcast. Given the cutthroat nature of competition with the likes of OneWeb, Telesat, LeoSat, and others, this is not guaranteed.

Pictured here after its second launch in January 2019, Falcon 9 B1049.3 is the likeliest candidate for Starlink-1. (Pauline Acalin)

At the end of the day, such a major leap into action bodes extremely well for SpaceX’s ability to realize its ambitious Starlink constellation, and do so fast. For those on Earth without reliable internet access or any access at all, the faster Starlink – and competing constellations, for that matter – can be realized, the sooner all of humanity can enjoy the many benefits connectivity can bring. For those that sit under the thumb of monopolistic conglomerates like Comcast and Time Warner Cable, relief will be no less welcome.

Stay tuned as we get closer to Starlink-1’s May 15th launch date. Up next is a static fire of the mission’s Falcon 9 rocket, perhaps just two or three days from now.

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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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Tesla VP explains latest updates in trade secret theft case

Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

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tesla 4680
Credit: Tesla Inc.

Tesla Vice President Bonne Eggleston explained the latest updates in a trade secret theft case the company has against a former manufacturing equipment supplier, Matthews International.

Back in 2024, Tesla had filed a lawsuit against Matthews International, alleging that the firm stole trade secrets about battery manufacturing and shared those details with some of Tesla’s competitors.

Early last year, a U.S. District Court Judge denied Tesla’s request to block Matthews International from selling its dry battery electrode (DBE) technology across the world. The judge, Edward Davila, said that the patent for the tech was due to Matthews’ “extensive research and development.”

Tesla is suing a former supplier for trade secret theft

The two companies’ relationship began back in 2019, as Tesla hired Matthews to help build the equipment for its 4680 battery cell. Tesla shared confidential software, designs, and know-how under strict secrecy rules.

Fast forward a few years, and Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

Now, the latest twist, as this month, a Judge issued a permanent injunction—a court order banning Matthews from using certain stolen Tesla parts or designs in their machines. Matthews is also officially “liable” for damages. The exact amount would still to be calculated later.

Bonne Eggleston, a VP for Tesla, said on X today that Matthews is a supplier who “exploited customer IP through theft or deception,” and has no place in Tesla’s ecosystem:

Tesla calls this a big win and warns other companies: “Buyer beware—don’t buy from thieves.”

Matthews hit back with a press release claiming victory. They say an arbitrator ruled they can keep selling their own DBE equipment to anyone and rejected Tesla’s request for a total sales ban. They call Tesla’s claims “nonsense” and insist their 20-year-old tech is independent. Both sides are spinning the same narrow ruling: Matthews can sell their version, but they’re blocked from using Tesla’s specific secrets.

What are Tesla’s Current Legal Options

The case isn’t over—it’s moving to the damages phase. Tesla can:

  • Push forward in court or arbitration to calculate and collect huge financial penalties (potentially $1 billion+ if willful theft is proven).
  • Enforce the permanent injunction with contempt charges, fines, or even jail time if Matthews violates it.
  • Challenge Matthews’ new patents that allegedly copy Tesla’s work, asking courts to invalidate them or add Tesla as co-inventor.
  • Seek extra damages, lawyer fees, and possibly punitive awards under the federal Defend Trade Secrets Act and California law.

Tesla could also refer evidence to federal prosecutors for possible criminal trade-secret charges (rare but serious). Settlement is always possible, but Tesla’s fiery public response suggests they want full accountability.

This isn’t just corporate drama. It shows why trade secrets matter even when Tesla open-sources some patents, confidential know-how shared in trust must stay protected. For the EV industry, it’s a reminder: steal from your biggest customer, and you risk losing everything.

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Tesla Cybercab includes this small but significant feature

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

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Credit: Tesla

Tesla Cybercab manufacturing is strikingly close, as the company is still aiming for an April start date. But small and significant features are still being identified for the first time as production units appear all over the country for testing and for regulatory events, like one yesterday in Washington, D.C.

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

This was for everyone, including the disabled, who are widely reliant on ride-sharing platforms, family members, and medical shuttles for transportation of any kind. Cybercab aims to change that, and Tesla evidently put a focus on those riders while developing the vehicle, evident in a small but significant feature revealed during its appearance in the Nation’s Capital.

Tesla Cybercab display highlights interior wizardry in the small two-seater

Tesla has implemented Braille within the Cybercab to make it easier for blind passengers to utilize the vehicle. On both the ‘Stop/Hazard Lights’ button and the Door Releases, Tesla has placed Braille so that blind passengers can navigate their way through the vehicle:

This is a great addition to the Cybercab, especially as Full Self-Driving has been partially pointed at as a solution for those with disabilities that would keep them from driving themselves from place to place.

It truly is a great addition and just another way that Tesla is showing they are making this massive product inclusive for everyone out there, including those who have not been able to drive due to not having vision.

The Cybercab is set to enter mass production sometime in April, and it will be responsible for launching Tesla’s massive plans for an autonomous ride-sharing program.

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Elon Musk

Tesla and xAI team up on massive new project

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

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Credit: Grok

Elon Musk teased a massive new project, to be developed jointly by Tesla and xAI, called “Digital Optimus” or “Macrohard,” the first development under Tesla’s investment agreement with xAI.

Musk announced on X that Digital Optimus will “be capable of emulating the function of entire companies.”

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

Essentially, it will be an AI version of a desk worker in many capacities, including accounting, HR tasks, and others.

Musk said:

“Grok is the master conductor/navigator with deep understanding of the world to direct digital Optimus, which is processing and actioning the past 5 secs of real-time computer screen video and keyboard/mouse actions. Grok is like a much more advanced and sophisticated version of turn-by-turn navigation software. You can think of it as Digital Optimus AI being System 1 (instinctive part of the mind) and Grok being System 2. (thinking part of the mind).”

Its key applications would be used for enterprise automation, simulating entire companies, high-volume repetitive tasks, and potentially, future hybrid use with the Optimus robot, which would handle physical tasks, while Digital Optimus would handle the clerical work.

Tesla announces massive investment into xAI

The creation of a digital AI suite like Digital Optimus would help companies save time and money, as well as become more efficient in their operations through massive scalability. However, there will undoubtedly be concerns from people who are skeptical of a fully-integrated AI workhorse like this one.

From an energy consumption perspective and just a general concern for the human workforce, these types of AI projects are polarizing in nature.

However, Digital Optimus would be a great digital counterpart to Tesla’s physical Optimus robot, as it would be a hyper-efficient addition to any company that is looking for more production for less cost.

Musk maintains that there is no other company on Earth that will be able to do this.

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