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SpaceX ships 200th Falcon second stage, highlighting the flip-side of booster reuse

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SpaceX has built and shipped its 200th Falcon second stage, highlighting the often underappreciated rocket’s record of achievement on the ground and in flight.

Approximately 13 years ago, in late 2009 or early 2010, SpaceX shipped the first flightworthy prototype of the first iteration of its Falcon 9 second stage. In June 2010, Falcon 9 lifted off on its inaugural test flight and, with the help of that second stage, successfully launched a boilerplate mockup of Dragon spacecraft into orbit. Since Falcon 9’s surprising inaugural success, SpaceX’s Falcon 9 and Falcon Heavy rockets have launched another 187 times for a total of 188 launches and 189 assembled rockets. Every one of those launches has required a new second stage, and all but one (Crew Dragon’s In-Flight Abort test) required a new Merlin Vacuum engine.

While SpaceX is most famous for the successful realization of rapidly reusable Falcon boosters, the company’s overall success is also inextricably linked to Falcon second stages, which are and always will be expended after every launch. For every spectacular Falcon booster landing or reuse record, a Falcon second stage either unceremoniously burns up in Earth’s atmosphere or finds itself stranded in orbit. As a result, even as SpaceX’s reusability has allowed it to launch more than ever before with a fleet of just 10-20 Falcon boosters, the company has had to expand the production of Falcon second stages extraordinary levels.

SpaceX just completed its 188th Falcon 9/Heavy launch, so the 200th flightworthy second stage and Merlin Vacuum (MVac) engine are probably scheduled to launch sometime in January 2023. In the last 365 days, SpaceX’s Falcon rockets have completed 59 successful orbital launches. Every launch has required a new second stage, so SpaceX, on average, has consistently built, shipped, and tested a new Falcon second stage every 6.2 days for more than a year.

Thanks to SpaceX’s record-breaking 2022 launch cadence, which has resulted in Falcon 9 launching more in one calendar year than any other rocket in history, the Falcon second stage has likely become the most-produced orbital rocket stage in decades. Barring surprises, SpaceX is on track to achieve CEO Elon Musk’s goal of 60 Falcon launches in 2022. But SpaceX isn’t done yet, and CEO Elon Musk says that the company is targeting “up to 100 launches” in 2023. After nearly doubling between early and late 2021, that will require Falcon second stage production to increase another ~67% year-over-year.

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In its 12.5-year career, Falcon 9 has suffered three failures. In October 2012, on its third launch, one of Falcon 9’s nine Merlin 1C booster engines failed in flight. The main mission – a Dragon cargo mission to the International Space Station – was saved by the second stage, which autonomously compensated for the lost performance, but a secondary payload (Orbcomm’s first OG2 satellite prototype) was lost as a result. In June 2015, a faulty strut inside Falcon 9’s second stage caused a helium pressure vessel to break loose and rupture, destroying the rocket mid-flight. And in September 2016, during a prelaunch static fire test, a similar pressure vessel inside an upgraded Falcon 9’s second stage spontaneously sparked, causing an explosion that destroyed the rocket while it was still on the ground.

As a result, while problems with Falcon second stages have technically caused both of Falcon 9’s only catastrophic failures, it’s still true that a free-flying Falcon second stage has never failed in flight. The same is true for the second stage’s Merlin Vacuum engine: over hundreds of burns and more than 70,000 seconds of operation, MVac has never failed in flight.

SpaceX announced the completion of its 100th MVac engine in April 2020, which means that it took ~130 months to build the first 100 and ~30 months to build the next 100. (SpaceX)

After Falcon 9’s successful November 3rd, 2022 launch of the Eutelsat Hotbird 13G communications satellite, SpaceX’s Falcon rocket family has completed 160 launches without failure, arguably making it the most reliable rocket family in history. To achieve that feat with its partially-reusable Falcon 9 and Falcon Heavy rockets, SpaceX has had to master reusable and expendable orbital rockets to a degree that only a few other companies or space agencies in history can claim to have matched or exceeded, and that none have achieved simultaneously.

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 expands Robotaxi app access once again, this time on a global scale

Tesla said recently it plans to launch Robotaxi in Miami, Houston, Las Vegas, Phoenix, and Dallas.

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Credit: Grok

Tesla has expanded Robotaxi app access once again, but this time, it’s on a much broader scale as the company is offering the opportunity for those outside of North America to download the app.

Tesla Robotaxi is the company’s early-stage ride-hailing platform that is active in Texas, California, and Arizona, with more expansion within the United States planned for the near future.

Tesla said recently it plans to launch Robotaxi in Miami, Houston, Las Vegas, Phoenix, and Dallas.

The platform has massive potential, and Tesla is leaning on it to be a major contributor to even more disruption in the passenger transportation industry. So far, it has driven over 550,000 miles in total, with the vast majority of this coming from the Bay Area and Austin.

First Look at Tesla’s Robotaxi App: features, design, and more

However, Tesla is focusing primarily on rapid expansion, but most of this is reliant on the company’s ability to gain regulatory permission to operate the platform in various regions. The expansion plans go well outside of the U.S., as the company expanded the ability to download the app to more regions this past weekend.

So far, these are the areas it is available to download in:

  • Japan
  • Thailand
  • Hong Kong
  • South Korea
  • Australia
  • Taiwan
  • Macau
  • New Zealand
  • Mexico
  • U.S.
  • Canada

Right now, while Tesla is focusing primarily on expansion, it is also working on other goals that have to do with making it more widely available to customers who want to grab a ride from a driverless vehicle.

One of the biggest goals it has is to eliminate safety monitors from its vehicles, which it currently utilizes in Austin in the passenger’s seat and in the driver’s seat in the Bay Area.

A few weeks ago, Tesla started implementing a new in-cabin data-sharing system, which will help support teams assist riders without anyone in the front of the car.

Tesla takes a step towards removal of Robotaxi service’s safety drivers

As Robotaxi expands into more regions, Tesla stands to gain tremendously through the deployment of the Full Self-Driving suite for personal cars, as well as driverless Robotaxis for those who are just hailing rides.

Things have gone well for Tesla in the early stages of the Robotaxi program, but expansion will truly be the test of how things operate going forward. Navigating local traffic laws and gaining approval from a regulatory standpoint will be the biggest hurdle to jump.

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Investor's Corner

Tesla gets price target boost, but it’s not all sunshine and rainbows

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Credit: Tesla Europe & Middle East/X

Tesla received a price target boost from Morgan Stanley, according to a new note on Monday morning, but there is some considerable caution also being communicated over the next year or so.

Morgan Stanley analyst Andrew Percoco took over Tesla coverage for the firm from longtime bull Adam Jonas, who appears to be focusing on embodied AI stocks and no longer automotive.

Percoco took over and immediately adjusted the price target for Tesla from $410 to $425, and changed its rating on shares from ‘Overweight’ to ‘Equal Weight.’

Percoco said he believes Tesla is the leading company in terms of electric vehicles, manufacturing, renewable energy, and real-world AI, so it deserves a premium valuation. However, he admits the high expectations for the company could provide for a “choppy trading environment” for the next year.

He wrote:

“However, high expectations on the latter have brought the stock closer to fair valuation. While it is well understood that Tesla is more than an auto manufacturer, we expect a choppy trading environment for the TSLA shares over the next 12 months, as we see downside to estimates, while the catalysts for its non-auto businesses appear priced at current levels.”

Percoco also added that if market cap hurdles are achieved, Morgan Stanley would reduce its price target by 7 percent.

Perhaps the biggest change with Percoco taking over the analysis for Jonas is how he will determine the value of each individual project. For example, he believes Optimus is worth about $60 per share of equity value.

He went on to describe the potential value of Full Self-Driving, highlighting its importance to the Tesla valuation:

“Full Self Driving (FSD) is the crown jewel of Tesla’s auto business; we believe that its leading-edge personal autonomous driving offering is a real game changer, and will remain a significant competitive advantage over its EV and non-EV peers. As Tesla continues to improve its platform with increased levels of autonomy (i.e., hands-off, eyes-off), it will revolutionize the personal driving experience. It remains to be seen if others will be able to keep pace.”

Additionally, Percoco outlined both bear and bull cases for the stock. He believes $860 per share, “which could be in play in the next 12 months if Tesla manages through the EV-downturn,” while also scaling Robotaxi, executing on unsupervised FSD, and scaling Optimus, is in play for the bull case.

Will Tesla thrive without the EV tax credit? Five reasons why they might

Meanwhile, the bear case is placed at $145 per share, and “assumes greater competition and margin pressure across all business lines, embedding zero value for humanoids, slowing the growth curve for Tesla’s robotaxi fleet to reflect regulatory challenges in scaling a vision-only perception stack, and lowering market share and margin profile for the autos and energy businesses.”

Currently, Tesla shares are trading at around $441.

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Tesla Optimus dramatically collapses after teleoperator mishap

It seemed blatantly obvious that whoever was controlling the Optimus robot from behind the scenes did not disconnect their ability to manipulate its movements

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Credit: @xdNiBoR | X

Tesla Optimus dramatically collapsed after a teleoperator mishap at the company’s “Future of Autonomy Visualized” event in Miami this past weekend.

It seemed blatantly obvious that whoever was controlling the Optimus robot from behind the scenes did not disconnect their ability to manipulate its movements, then left the controls, causing Optimus to collapse.

A video captured at the event shows Optimus doing a movement similar to taking a headset off, likely what the teleoperator uses to hear guest requests and communicate with other staff:

After the headset removal motion was completed, Optimus simply collapsed backward, making for an interesting bit of conversation. While it was a mishap, it was actually pretty funny to watch because of the drama displayed by the robot in the situation.

This was obviously a mistake made by the teleoperator, and does not appear to be a spot where we can put any sort of blame on Optimus. It would have likely just stood there and waited for controls to resume if the teleoperator had disconnected from the robot correctly.

However, details are pretty slim, and Tesla has not announced anything explaining the situation, likely because it seems to be a pretty face-value event.

Tesla Optimus shows off its newest capability as progress accelerates

The Tesla Optimus program has been among the most hyped projects that the company has been working on, as CEO Elon Musk has extremely high hopes for what it could do for people on Earth. He has said on several occasions that Optimus should be the most popular product of all time, considering its capabilities.

Obviously, the project is still a work in progress, and growing pains are going to be part of the development of Optimus.

In its development of Optimus Gen 3, Tesla has been working on refining the forearm, hand, and fingers of Optimus, something that Musk said is extremely difficult. However, it’s a necessary step, especially if its capabilities will not be limited by hardware.

All in all, Optimus has still been a very successful project for Tesla, especially in the early stages. The company has done an excellent job of keeping Optimus busy, as it helps with serving customers at events and the Tesla Diner, and is also performing tasks across the company’s manufacturing plants.

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