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

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SpaceX’s Starlink satellite internet was tested by the US Air Force and the results are in

A render of several Starlink satellites in orbit. SpaceX hopes to launch nearly 1500 of the spacecraft in 2020. (SpaceX)

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SpaceX President and Chief Operating Officer Gwynne Shotwell recently provided information about the company’s Starlink satellite internet constellation after a panel at the International Aeronautical Congress in Washington D.C. Shotwell spoke of a partnership with the U.S. military and just how far she believes Starlink is ahead of rival mega-constellation efforts.

While competitors are still developing very early prototypes and worrying about launch options, SpaceX has already launched 60 Starlink ‘v0.9’ satellite prototypes, 50 of which continue to successfully operate in low Earth orbit approximately half a year after launch. As part of a $29M contract awarded in late-2018, SpaceX is also working directly with the U.S. Air Force to test military applications of commercial space-based internet.

As previously reported by Teslarati, SpaceX was awarded a $29 million contract in December 2018 to collaborate with the U.S. Air Force Strategic Development Planning and Experimentation Office. Together, the organizations are testing potential military applications of Starlink satellite internet, as well as prospective constellations from other companies like Telesat.

From LEO to aircraft

The MC-12 is operated by the US military in a range of roles, including work as an avionics testbed. (USAF – Tiffany Trojca)

The technical viability and utility of beaming high speed, low-latency broadband internet directly into the cockpits of military aircraft is being tested under a program called Global Lightning. SpaceX has engaged the initiative and was awarded $29M to pursue development and testing, far more than any other contract recipient. In October 2019, SpaceX and the USAF began publicly discussing the latest results of that effort to test Starlink’s capabilities in the realm of in-flight connectivity. As reported by SpaceNews, SpaceX COO Gwynne Shotwell revealed that Starlink had successfully demonstrated a data link to the cockpit of a military aircraft with a bandwidth of 610 megabits per second (Mbps), equivalent to a gigabyte every ~13 seconds.

Following a previous speaking engagement on Oct. 15th at the Association of the U.S. Army’s annual conference, Shotwell and U.S. Army officials provided further insight regarding military applications of Starlink. Army officials spoke about the possibility of using Starlink satellite internet and other prospective constellations to support the military’s rapidly growing demand for high-speed communications.

During the panel with U.S. Army officials, Shotwell stated that “SpaceX is new to this forum and this service,” when addressing the possibilities that SpaceX could provide for the U.S. military. While working with the military is not a new concept to SpaceX, serving as a satellite communications provider would be unlike anything the company has yet attempted.

Up next, the USAF has plans to install Starlink terminals and test connectivity with an AC-130 gunship and a KC-135 tanker aircraft.

Falcon 9 to support frequent Starlink launches – customers and rocket reusability benefit

While Shotwell acknowledged the potential of a partnership with the US. military, she also noted that Starlink is first and foremost a commercial business meant to enhance the internet experience globally and nominally provide connectivity to anyone that wants it. She further noted that Starlink would remain an “additive to [SpaceX’s] business,” implying that it will not supersede SpaceX’s current launch service business.

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Intriguingly, this is utterly counter to forecasts SpaceX has provided investors over the last several years, in which Starlink – if successful – would almost certainly come to produce one or two magnitudes more income than launch services ever could. Shotwell – speaking to a variety of US military (and Air Force) officials – may have wanted to avoid sending the message that SpaceX’s launch services business – crucial to the US military – might soon be absolutely dwarfed by Starlink revenue.

A general overview of Starlink’s bus, launch stack, and solar array. (SpaceX)

Previously hinted at by CEO Elon Musk, SpaceX hopes that revenue from Starlink will enable the company to independently fund the development and mass-production of its next-generation Starship launch vehicle, eventually enabling a permanent, large-scale human presence on Mars.

Currently, SpaceX’s Starlink plans involve several distinct phases, beginning with ~1500 satellites around 500km, another ~2900 around 1000 km, and an additional ~7500 in the 300-400 km range. Finally, SpaceX recently revealed even longer-term plans for Starlink that could involve launching up to 42,000 satellites, all in the name of expanding network coverage and bandwidth – pending, of course, consumer demand. To accomplish that feat, SpaceX will have to push rocket reusability to the absolute limits, beginning with Falcon 9 boosters and fairings and ultimately moving to Starship. According to Shotwell, “(SpaceX’s) intent is to use Starlink to push the capability of those boosters and see how many missions they can do.”

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)
SpaceX’s first Starlink v0.9 mission suffered two false-starts but was soon followed by a successful launch debut in May 2019. (SpaceX)

SpaceX’s next Starlink mission – also the company’s next mission and first launch in more than three months – will simultaneously attempt two new rocket reusability firsts, marking the first time that SpaceX has reused a Falcon payload fairing and the first time a single Falcon 9 booster has launched four times. Starlink-1 is scheduled to lift off no earlier than 9:55 am ET (14:55 UTC), November 11th.

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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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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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