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SpaceX’s second Starlink Gen2 launch could set payload record [webcast]

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SpaceX’s second Starlink Gen2 launch will carry 56 satellites, potentially making it the heaviest payload the company has ever launched.

At 9:30 am EST, SpaceX completed a static fire of the two-stage Falcon 9 rocket assigned to launch its next Starlink mission. Half an hour later, SpaceX confirmed that the rocket performed well and is scheduled to launch no earlier than 4:32 am EST (09:32 UTC) on Thursday, January 26th. SpaceX didn’t state the mission’s purpose, but shorthand (“sl5-2”) used in an official website URL implies that it will be the second launch for its Starlink Gen2 satellite constellation.

SpaceX also reported that Starlink 5-2 will carry 56 satellites, meaning that the mission could set a new Falcon 9 payload record.

56 is not a record number of satellites for a SpaceX launch or a Starlink launch. SpaceX has launched a record 143 rideshare payloads at once, and the company routinely launched 60 Starlink satellites at a time throughout 2019, 2020, and part of 2021. But those Starlink satellites were the first versions (V1.0) of the spacecraft and weighed either 227 or 260 kilograms (500/570 lbs) apiece.

In the second half of 2021, SpaceX began launching new Starlink V1.5 satellites. Outfitted with new laser links (optical terminals) and other general upgrades, the new satellites reportedly weigh 303, 307, or 309 kilograms (668, 676, or 681 lb) each. The heavier design forced SpaceX to slightly reduce the number of satellites each launch could carry. After some optimization, SpaceX regularly launches up to 54 Starlink V1.5 satellites at a time, down from 60 V1.0 satellites.

The number of satellites may be smaller, but the mass of the payload launched has never been higher. SpaceX last broke Falcon 9’s payload mass record in August 2022, when it launched 54 Starlink V1.5 satellites for the first time. The payload reportedly weighed 16.7 tons (~36,800 lb), breaking the previous record of 16.25 tons by about 3%. The heaviest 60-satellite Starlink V1.0 payload weighed around 15.6 tons (~34,400 lb).

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Stacks of Starlink V1.0 and V1.5 satellites. (SpaceX)

Now, SpaceX says it will launch 56 Starlink satellites – likely heavier V1.5 variants – at once. If SpaceX hasn’t reduced the weight of each satellite, the payload could weigh anywhere from 16.97 to 17.3 tons (37,400-38,200 lb). Starlink 5-2 is targeting the same orbit as Starlink 5-1, which carried 54 satellites. The likeliest explanation for the heavier payload appears to be another iterative improvement to Falcon 9.

As SpaceX gains confidence in and experience with Falcon 9, it’s been able to tweak the timing of certain launch events, raise performance limits, and reduce certain margins. If Starlink 5-2’s Starlink satellites are unchanged, SpaceX’s tweaks will have collectively boosted Falcon 9’s performance by ~10% (15.6 to ~17 tons) in two years.

Gen1, V1.0, V1.5, Gen2, V2.0

Starlink 5-2 also continues the trend of confusion created by the company’s first Starlink Gen2 launch, which it deemed Starlink 5-1. The naming scheme implied that the satellites were a continuation of the company’s first constellation, Starlink Gen1, but SpaceX confirmed that they were actually the first Starlink Gen2 satellites. That SpaceX is launching 54 (and now 56) satellites also confirms that they are likely the same V1.5 satellites the company has been launching for 18 months.

SpaceX CEO Elon Musk has outright stated that the company could go bankrupt if it couldn’t begin launching much larger Starlink V2.0 satellites on its Starship rocket in the near future. Instead, SpaceX is doing the exact opposite and is populating its Starlink Gen2 constellation with Gen1-sized satellites. It’s unclear when SpaceX will begin launching the larger Starlink V2.0 satellites that were meant to be the mainstay of the Gen2 constellation.

Tune in below around 4:25 am EST (09:15 UTC), January 25th, to watch SpaceX’s second Starlink Gen2 launch live.

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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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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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.

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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