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SpaceX’s Starlink successes secure US military contract for custom satellites

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SpaceX has won $149 million from the Space Development Agency (SDA) to leverage the successes of its Starlink constellation and build custom satellites for the US Department of Defense (DoD).

The development comes as no surprise after SpaceX spent more than six months publishing dozens of job openings for satellite design, development, test, and integration engineers with “top secret” security clearance. Thanks to that paper trail, it’s been apparent for quite some time that SpaceX planned to leverage its nascent satellite design and production capabilities to build custom spacecraft – and even entire constellations – for customers outside of the company.

Perhaps less than coincidentally, that capability closely mirrors a growing desire in the US military to return some level of agility, innovation, and affordability to the development and procurement of space systems (mainly satellites and the ground systems needed to control and communicate with them).

An artist’s conception of Starlink satellites in orbit. (Teslarati – SpaceX)

In classic US military fashion, SDA’s contracts appear to mirror DARPA’s (Defense Advanced Research Projects Agency) own Blackjack program. According to DARPA, the “Blackjack program aims to develop and demonstrate the critical elements for a global high-speed network in low Earth orbit (LEO) that provides the Department of Defense with highly connected, resilient, and persistent coverage.” At one point, SDA was seriously considering a role in DARPA’s Blackjack but had no plans to put money where its mouth was as recently as February 2020.

However, in a June 2020 interview, Blackjack project manager Paul Thomas deemed SDA a “very, very awesome partner” that will be directly involved in the launch of two early Blackjack testbed satellites later this year – to be followed by a “subconstellation” (~20 satellites) in 2022.

SDA’s October 5th, 2020 contract awarded SpaceX and L3Harris $149 million and $193 million, respectively, to build four satellites that will spot and track missile launches with wide-field-of-view (WFOV) “overhead persistent infrared” (OPIR) sensors. SDA expects the spacecraft to be ready for launch by September 2022. SpaceX will outsource its OPIR sensors to an unknown company, while L3Harris – already an expert of complex sensor design and production – will build and integrate its own. Bizarrely, DARPA awarded Raytheon $37 million in June 2020 to build and deliver two OPIR sensors for Blackjack satellites by April 2023 – seemingly unrelated to SDA’s October 2020 contract for eight OPIR satellites.

If things go as planned, the eight OPIR satellites SDA is paying $342 million to develop and launch will be the start of a 30-satellite “Tracking Layer” constellation. The Tracking Layer constellation will integrate with a separate “Transport Layer” of 20 laser-interlinked relay satellites to be built by Lockheed Martin ($187.5M) and York Space Systems ($94M) for ~$282 million and launched by September 2022.

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Ultimately, it’s ambiguous just how closely SDA and DARPA are working on what currently appear to be separate, partially duplicative constellations of small satellites. Relative to DARPA’s Blackjack program, SDA is pursuing a far more ambitious schedule and has wagered far more resources (more than half a billion dollars) on its plans for a new missile-warning satellite constellation. If SpaceX, L3Harris, Lockheed Martin, and York Space Systems complete their respective work on schedule, SDA could effectively go from the drawing board to an unprecedentedly affordable constellation of 50 cutting-edge satellites in just 28 months – and all while spreading its risk between four unique companies.

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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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Tesla Optimus Gen 3 shows off a cleaner, factory-ready design in new app discovery

Renders hidden inside Tesla’s Android app show Optimus Gen 3’s design before any official reveal.

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla may have accidentally given a first look at its newest Optimus Gen 3 humanoid robot when photos were found in the Tesla smartphone app.

Design files tucked inside a recent Android version of the Tesla app appear to show the third generation humanoid robot next to the older Gen 2.5 prototype. The assets were extracted from the app package by Tesla community member @wholemars, who posted the renders on X late Tuesday night before deleting them. The Tesla Newswire reshared the side by side comparison on Wednesday, and the images have circulated widely since.

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

The files are labeled “gen3” and were built as models for Tesla app’s own interface, as validated directly by Grok to be official.

The comparison shows a robot that looks built for a factory line rather than a lab bench. Gen 2.5’s exposed mechanical linkages and gold plating on the knees and shins are gone. In their place, Gen 3 uses matte black fairings on the lower legs, paired with a more contoured champagne gold body. Flexible covers now seal the joint where the torso meets the upper thighs, keeping bearings and moving parts sealed from debris and unnecessary contact.

The body panels fit more tightly, and the hands, which Tesla has said carry 22 degrees of freedom, look far more refined than those on earlier units.

This most recent leak fills a gap Tesla has left open for most of the year. Elon Musk said on March 31 that Optimus 3 was walking around but needed “some finishing touches” before it could be shown, a delay Teslarati covered when Tesla missed its first quarter reveal target. Musk later said Tesla would hold the design back until closer to production, partly to keep competitors from copying it. No reveal date has been announced.

The app itself has been preparing for Optimus for months. In July, code in the Tesla app pointed to a dedicated robot phone key, a consent screen for collecting video and spatial data while Optimus works inside a home, and an alert system for low battery and mechanical faults. Finished 3D models of Gen 3 suggest the interface owners will eventually use is moving past placeholder code toward something Tesla intends to ship.

Manufacturing is moving in parallel. Tesla tore out the original Model S and Model X lines at Fremont this summer to make room for Optimus production, with a planned capacity of one million robots a year. At Giga Texas, the steel frame of a dedicated Optimus factory is nearing completion ahead of a targeted 2027 start, with Musk pointing to an eventual output of 10 million units annually.

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Tesla Semi lands the biggest electric truck deal in U.S. history

Tesla leads a record 2,500 truck order, but not every truck will be a Semi.

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Tesla has landed the largest electric truck order in U.S. history. ZET SCALE, a new alliance of shippers and carriers, named Tesla its primary manufacturer on Tuesday for an initial order of 2,500 electric Class 8 trucks. The deal alone would nearly double the number of electric heavy trucks operating in the country.

According to the press release from Catalyst Mobility, the nonprofit formerly known as CALSTART, Kenworth, RIDE and Volvo were also selected as secondary manufacturers that carriers can pick if their operations call for it. No split between the four brands has been published, so the exact number of Semis in the order is not yet known.

Tesla won the top slot through a competitive request for proposals. The alliance, which Catalyst Mobility runs with the Smart Freight Centre, scored bidders on price, range, charging capability and production capacity. Pooling freight demand from founding shippers, including Microsoft and PepsiCo, let every truck maker bid lower than it would for a single fleet. “The Tesla Semi is designed for lower cost per mile operations than diesel,” said Dan Priestley, director of the Tesla Semi program, as noted in the press release.

The financing is built to pull in carriers who have avoided electric trucks. ZET Financial is issuing the purchase order for all 2,500 units and will place them with fleets through a fair market value lease. The trucks will be deployed over the next few years across 10 freight hubs in Los Angeles, Stockton, Bakersfield, Seattle and Tacoma, Houston, Dallas, San Antonio, Chicago, Atlanta, and the Newark and New York area. ZET SCALE says the first order is only the opening round, with a longer term goal of 10,000 trucks or more.

Even if Tesla ends up with only a majority share, it would still be the biggest Semi deal to date. Einride’s 500 unit order in August was the previous record, and WattEV’s 370 truck order in May was the largest California deal at the time. Einride’s CEO has since said he expects all 500 trucks delivered by the end of 2027.

The announcement lands two days before Tesla formally inaugurates its Semi factory in Nevada on September 24. The 1.7 million square foot plant sits next to Gigafactory Nevada’s 4680 cell lines and is designed for 50,000 trucks a year.

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Tesla integrates Grok Bot into its vehicles for the ultimate personal assistant

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Credit: Grok

Tesla has expanded Grok from an in-car chatbot into a hands-free work assistant. On September 22, Tesla officially launched Grok Bot capability, confirming that drivers can now manage email, calendars, files, chats, and tasks by voice and then hand more ambitious errands to the AI-fueled productivity cheat code.

Grok itself is built by xAI. The new car features split into two layers: Connectors link Grok to outside accounts. Grok Bot, currently limited to SuperGrok Heavy subscribers, can complete multi-step tasks such as placing a usual coffee order, booking a reservation, or scheduling an appointment. It truly puts the driver in a nearly complete hands-free driving and productivity setting, with ironically the only task truly requiring your hands being to touch the “Start Self-Driving” button.

We were granted access to Grok Bot’s Tesla integration a few weeks back, and we’ve been able to do a handful of things with it. On a handful of occasions, we’ve used it to order food and have it ready for pickup slightly later into the evening; we’ve managed to pick up groceries after a day of errands with Grok Bot, and outside of the car, it’s helped with budgeting and even my fantasy football draft.

Tesla shows another way to utilize it: in their demo, a driver says “Hey Grok,” asks the assistant to check an inbox, and hears that a message concerns a weekend reservation. Grok then scans the calendar, reports no conflicts, and confirms the Tahoe trip is clear. It can also add check-in details to a road-trip itinerary. The point is not novelty chat. It is keeping eyes on the road, or on Full Self-Driving, while the car handles the paperwork of a trip:

This Grok rollout is not a gadget add-on as much as it is Tesla’s thesis in software form: the car should stop being a machine you operate and start being a room you occupy.

Connectors and Grok Bot treat the cabin as an office that happens to move, and that has truly been Tesla’s intention for years now. The car has slowly become an extension of a home more than a vehicle. Inbox, calendar, groceries, takeout, and reservations become voice work, not dashboard chores that you need to do before you get in your car.

Responsibility shifts from the driver to the stack, and as many Tesla owners rely on FSD for travel, Grok Bot now handles the monotony of dinner reservations or appointments.

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