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SpaceX Starlink launch marks record Falcon fairing reuse, 85th booster landing

SpaceX's 14th Starlink launch of 2021 is set to mark the first time a Falcon fairing half flies for the fifth time. (Richard Angle)

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Update: SpaceX aced its 28th operational Starlink launch without issue, simultaneously marking a new record for Falcon fairing reuse, the 85th successful Falcon booster landing, and Falcon’s 94th consecutively successful launch.

SpaceX says that its 14th Starlink launch of 2021 will also be the first mission to fly a reusable Falcon payload fairing for the fifth time, marking a significant milestone just 18 months after fairing reuse began.

Scheduled to lift off no earlier than (NET) 2:59 pm EDT (18:59 UTC) on Wednesday, May 26th, Starlink-28 will be SpaceX’s 12th dedicated Starlink launch and 14th Starlink launch overall this year – representing more than 780 satellites safely delivered to orbit in five months. Perhaps most notably, Starlink-28 – if successful – will push SpaceX past a milestone that COO and President Gwynne Shotwell recently stated would enable virtually uninterrupted Starlink coverage of the populated world.

SpaceX says that Starlink-28 will fly with two flight-proven payload fairing halves – one having previously supported four Starlink missions and the other a Starlink mission and Transporter-1. Falcon fairings are vast nosecone-like structures built mainly out of carbon fiber and aluminum honeycomb composites and designed to maintain a sterile, controlled environment for satellites and protect them from the elements, heating, and aerodynamic stress while inside Earth’s atmosphere. SpaceX currently uses the same fairing design for all Falcon 9 and Falcon Heavy satellite launches, simplifying its product line to keep costs as low as possible.

Historically, SpaceX executives have stated that each pair of Falcon fairings represents around 10% of the cost of Falcon 9 production, or $5 million. Due to the need for massive autoclave curing ovens, the volume and speed of Falcon fairing production has a firm lower limit save for expensive, space-hungry factory expansions. For SpaceX’s increasingly ambitious Starlink launch cadence goals, that means that fairing recovery and reuse is more valuable and essential than each pair’s price tag would otherwise suggest.

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SpaceX reused a fairing for the first time on November 10th, 2019. (SpaceX)

SpaceX reused Falcon fairings for the first time on Starlink’s first operational v1.0 satellite launch in November 2019, approximately 18 months ago. Since then, of 28 operational Starlink missions, only 11 have flown new fairings, more than doubling the effective output of SpaceX’s limited fairing production capacity. All told, SpaceX has flown 34 flight-proven fairing halves on 19 separate missions – almost every other Falcon 9 launch since November 2019.

Starlink-28 will fly one of its two fairing halves for the fifth time just 18 months after the first fairing reuse. In comparison, SpaceX’s Falcon booster reusability program took three years – 36 months – to go from first reuse to a fifth flight of the same booster. In other words, SpaceX fairing reusability is speeding right along as it crosses milestones more than twice as quickly as boosters did. Over the brief life of the program, fairing reuse has likely already saved SpaceX at least $90 million in nonrecurring costs while simultaneously freeing up a substantial portion of the company’s composites team to fill in on other composites projects and reducing or replacing the need for tens of millions of dollars of new production space and equipment.

One of the fairing halves pictured here will fly for the third time on Starlink-28. (Richard Angle)

Tune in at the link below around 2:45 pm EDT (18:45 UTC) to watch SpaceX’s Starlink-28 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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Tesla FSD fleet is nearing 7 billion total miles, including 2.5 billion city miles

As can be seen on Tesla’s official FSD webpage, vehicles equipped with the system have now navigated over 6.99 billion miles.

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Tesla’s Full Self-Driving (Supervised) fleet is closing in on almost 7 billion total miles driven, as per data posted by the company on its official FSD webpage. 

These figures hint at the massive scale of data fueling Tesla’s rapid FSD improvements, which have been quite notable as of late.

FSD mileage milestones

As can be seen on Tesla’s official FSD webpage, vehicles equipped with the system have now navigated over 6.99 billion miles. Tesla owner and avid FSD tester Whole Mars Catalog also shared a screenshot indicating that from the nearly 7 billion miles traveled by the FSD fleet, more than 2.5 billion miles were driven inside cities. 

City miles are particularly valuable for complex urban scenarios like unprotected turns, pedestrian interactions, and traffic lights. This is also the difference-maker for FSD, as only complex solutions, such as Waymo’s self-driving taxis, operate similarly on inner-city streets. And even then, incidents such as the San Francisco blackouts have proven challenging for sensor-rich vehicles like Waymos. 

Tesla’s data edge

Tesla has a number of advantages in the autonomous vehicle sector, one of which is the size of its fleet and the number of vehicles training FSD on real-world roads. Tesla’s nearly 7 billion FSD miles then allow the company to roll out updates that make its vehicles behave like they are being driven by experienced drivers, even if they are operating on their own. 

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So notable are Tesla’s improvements to FSD that NVIDIA Director of Robotics Jim Fan, after experiencing FSD v14, noted that the system is the first AI that passes what he described as a “Physical Turing Test.” 

“Despite knowing exactly how robot learning works, I still find it magical watching the steering wheel turn by itself. First it feels surreal, next it becomes routine. Then, like the smartphone, taking it away actively hurts. This is how humanity gets rewired and glued to god-like technologies,” Fan wrote in a post on X. 

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Tesla starts showing how FSD will change lives in Europe

Local officials tested the system on narrow country roads and were impressed by FSD’s smooth, human-like driving, with some calling the service a game-changer for everyday life in areas that are far from urban centers.

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Credit: Grok Imagine

Tesla has launched Europe’s first public shuttle service using Full Self-Driving (Supervised) in the rural Eifelkreis Bitburg-Prüm region of Germany, demonstrating how the technology can restore independence and mobility for people who struggle with limited transport options. 

Local officials tested the system on narrow country roads and were impressed by FSD’s smooth, human-like driving, with some calling the service a game-changer for everyday life in areas that are far from urban centers.

Officials see real impact on rural residents

Arzfeld Mayor Johannes Kuhl and District Administrator Andreas Kruppert personally tested the Tesla shuttle service. This allowed them to see just how well FSD navigated winding lanes and rural roads confidently. Kruppert said, “Autonomous driving sounds like science fiction to many, but we simply see here that it works totally well in rural regions too.” Kuhl, for his part, also noted that FSD “feels like a very experienced driver.”

The pilot complements the area’s “Citizen Bus” program, which provides on-demand rides for elderly residents who can no longer drive themselves. Tesla Europe shared a video of a demonstration of the service, highlighting how FSD gives people their freedom back, even in places where public transport is not as prevalent.

What the Ministry for Economic Affairs and Transport says

Rhineland-Palatinate’s Minister Daniela Schmitt supported the project, praising the collaboration that made this “first of its kind in Europe” possible. As per the ministry, the rural rollout for the service shows FSD’s potential beyond major cities, and it delivers tangible benefits like grocery runs, doctor visits, and social connections for isolated residents. 

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“Reliable and flexible mobility is especially vital in rural areas. With the launch of a shuttle service using self-driving vehicles (FSD supervised) by Tesla in the Eifelkreis Bitburg-Prüm, an innovative pilot project is now getting underway that complements local community bus services. It is the first project of its kind in Europe. 

“The result is a real gain for rural mobility: greater accessibility, more flexibility and tangible benefits for everyday life. A strong signal for innovation, cooperation and future-oriented mobility beyond urban centers,” the ministry wrote in a LinkedIn post

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Tesla China quietly posts Robotaxi-related job listing

Tesla China is currently seeking a Low Voltage Electrical Engineer to work on circuit board design for the company’s autonomous vehicles.

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Credit: Tesla

Tesla has posted a new job listing in Shanghai explicitly tied to its Robotaxi program, fueling speculation that the company is preparing to launch its dedicated autonomous ride-hailing service in China. 

As noted in the listing, Tesla China is currently seeking a Low Voltage Electrical Engineer to work on circuit board design for the company’s autonomous vehicles.

Robotaxi-specific role

The listing, which was shared on social media platform X by industry watcher @tslaming, suggested that Tesla China is looking to fill the role urgently. The job listing itself specifically mentions that the person hired for the role will be working on the Low Voltage Hardware team, which would design the circuit boards that would serve as the nervous system of the Robotaxi. 

Key tasks for the role, as indicated in the job listing, include collaboration with PCB layout, firmware, mechanical, program management, and validation teams, among other responsibilities. The role is based in Shanghai.

China Robotaxi launch

China represents a massive potential market for robotaxis, with its dense urban centers and supportive policies in select cities. Tesla has limited permission to roll out FSD in the country, though despite this, its vehicles have been hailed as among the best in the market when it comes to autonomous features. So far, at least, it appears that China supports Tesla’s FSD and Robotaxi rollout.

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This was hinted at in November, when Tesla brought the Cybercab to the 8th China International Import Expo (CIIE) in Shanghai, marking the first time that the autonomous two-seater was brought to the Asia-Pacific region. The vehicle, despite not having a release date in China, received a significant amount of interest among the event’s attendees. 

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