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A stack of 60 Starlink v0.9 satellites are prepared for their orbital launch debut in May 2019. (SpaceX) A stack of 60 Starlink v0.9 satellites are prepared for their orbital launch debut in May 2019. (SpaceX)

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SpaceX planning four more Falcon 9-launched Starlink missions this year, permits show

An imposing stack of SpaceX's first 60 Starlink satellites is shown here prior to their inaugural launch. (SpaceX)

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According to a suite of eight FCC Special Temporary Authority licenses SpaceX filed for on August 30th, the company has plans for as many as four additional Starlink satellite launches in 2019, on top of Starlink’s May 23rd launch debut.

Additionally, SpaceX simultaneously requested that the FCC modify its current Starlink application to permit a slight change in orbital characteristics that would drastically improve the broadband satellite constellation’s coverage in its early stages. Combined, SpaceX appears to be extremely confident about the status and near-future progress to be made by its prospective Starlink constellation, confidence presumably inspired by the performance of the first 60 “v0.9” satellites launched three months ago.

Beta-test hiccups

Over the last three months, 50 of the 60 Starlink satellites launched on May 23rd have made their way to their final ~550 km (340 mi) circular orbits. As observed by astronomer Jonathan McDowell and partially confirmed by SpaceX’s own official statements, the company remains in contact with and – more or less – in control of all but three of the 60 Starlink prototypes. SpaceX did confirm in late June that two functioning satellites were being intentionally deorbited to test procedures and performance, while another three satellites had partially failed and were to “passively deorbit”.

Based on the phrasing of SpaceX’s June 28th update, it’s ambiguous if communication and/or control has been completely lost with those three satellites. Additionally, five more satellites have remained paused partway between their ~440 km insertion orbits and ~550 km operational orbits, described two months ago as “going through checkouts prior to completing their orbit raise.” For unknown reasons, that orbit raise never happened. This leaves SpaceX with 57 of 60 satellites that have effectively ‘survived’ and are still under some form of control, while 50 (83%) of the satellites have successfully reached their nominal operational orbits and are performing as intended.

SpaceX continues to waffle between describing these first 60 satellites – internally known as “Starlink v0.9” – as a development test and the first operational Starlink launch. A ~17% failure rate for satellite orbit raising would be unacceptable for a finished product but, on a positive note, is actually quite impressive if one assumes that the 60 spacecraft are high-fidelity prototypes, not operational satellites.

Although each satellite is just a few square meters, they may be able to serve internet to thousands of people simultaneously. (SpaceX)

In short, there is a lot of room for improvement – particularly in the realm of short and long-term reliability – but the likely fact that “v0.9” signifies a sort of Starlink beta test means that SpaceX’s next Starlink launches will feature updated and bug-fixed hardware. In the realm of satellites, the practice of flying prototypes as early as possible and risking failures to learn from experience is exceedingly rare, but this behavior is entirely consistent with SpaceX’s preferred approach to rocket and spacecraft development.

300 satellites, 7 months

As mentioned above, SpaceX applied for four FCC STA licenses – effectively communications-related launch permits – on August 30th, all for Starlink missions with nominal No Earlier Than (NET) launch dates in 2019. It must be noted that it’s exceptionally rare for the starting dates of STAs to actually correlate with launch dates, but a best-case scenario typically sees a given launch occur within a handful of weeks of that date. STAs last six months, providing plenty of buffer for all but the most extreme launch delays.

MissionDate (NET)
Starlink-1October 10th
Starlink-2October 25th
Starlink-3November 13th
Starlink-4December 8th

Of note, NASASpaceflight.com recently published Cape Canaveral Air Force Station (CCAFS) and Kennedy Space Center (KSC) planning dates for SpaceX’s next two Starlink missions, confirming that the company is planning for launches roughly one week after the dates on its newly-requested FCC STAs. Those official planning dates show two back-to-back Starlink launches no earlier than (NET) October 17th and November 4th.

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A general overview of Starlink’s bus, payload stacking, and solar arrays. (SpaceX)

In a best-case scenario where SpaceX successfully manufactures, delivers, and prepares the satellites and readies the Falcon 9 rockets assigned to launch them, the company could complete four more Starlink launches between now and the New Year. Sticking to a three-week cadence hopefully set by Starlink-1 and Starlink-2, two more launches could follow around late-November and mid-December. Of course, as just the first few truly operational launches of more or less finalized “v1.0” Starlink satellites, delays from manufacturing through launch flows are probable and should be expected.

Even completing just one more 60-satellite launch of an updated Starlink design would be an impressive achievement, making SpaceX the first and only entity – country or company – to place more than 100 satellites in orbit in the first year of a satellite system’s launch activities. In a best-case scenario, four additional Starlink launches in 2019 would abruptly take SpaceX from two satellite prototypes to operating almost 300 satellites – unequivocally the largest constellation in the world – in no more than seven months.

SpaceX's first Starlink launch was also Falcon 9 booster B1049's third launch ever.(SpaceX/Teslarati)
SpaceX completed its first Starlink launch on May 23rd, flying B1049 for the third time. SpaceX’s next Starlink launch will very likely mark the first time a booster has flown four orbital-class missions. (SpaceX)

Serving customers sooner

According to SpaceX’s Starlink.com website, Starlink will be able to start serving customers at Northern US and southern Canadian latitudes after just six launches (360 satellites), with limited “global coverage of the populated world” available after 24 launches (1440 satellites). However, per an FCC license modification request published on August 30th, the same day as 8 launch STAs, the company believes it can dramatically expedite Starlink coverage (regardless of launch rate) with one relatively simple modification.

This modification would leave inclination (orbit angle relative to Earth’s rotational axis), orbital altitude, and the number of satellites and launches completely unchanged, modifying Starlink’s orbital planes instead. It’s an extreme simplification of the reality of orbital mechanics, but one can imagine orbital planes as roughly akin to lanes on a road. To increase their reach, SpaceX wants to deploy Starlink satellites to three separate planes each launch, ultimately tripling the number of ‘lanes’ (from 24 to 72) while cutting the number of satellites in each ‘lane’ by two-thirds (from 66 to 22). In this analogy, it is logically easier to build fewer ‘lanes’, referring – in this case – to the challenge it poses to the launch vehicle, satellites, or both. SpaceX would only be able to triple Starlink’s orbital ‘lanes’ by requiring the satellites to do the bulk of their own orbit raising, leaning heavily on the performance and reliability of their SpaceX-built electric (ion) propulsion.

According to SpaceX, this could as much as halve the number of launches needed to achieve a given level of Starlink coverage, meaning that SpaceX’s early constellation could reach its initial operational status up to twice as quickly. SpaceX believes that this updated orbital layout of Starlink’s 1584 low Earth orbit (LEO) satellites would also significantly improve coverage and capabilities for areas with high population density (i.e. big cities).

Whether or not the FCC sees fit to rapidly grant SpaceX’s modification request in the next ~8 weeks, SpaceX’s next Starlink launches will be a major step forward for the company’s nascent communications constellation.

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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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Investor's Corner

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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Investor's Corner

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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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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