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SpaceX's three surviving thrice-flown Block 5 boosters - B1048, B1049, and B1046 - are pictured here in various stages of recovery. (Teslarati, Pauline Acalin) SpaceX's three surviving thrice-flown Block 5 boosters - B1048, B1049, and B1046 - are pictured here in various stages of recovery. (Teslarati, Pauline Acalin)

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SpaceX sets new Falcon 9 Block 5 reusability milestones for second half of 2019

Falcon 9 B1048, B1049, and B1046 pictured in various stages of their most recent launches. Together, the three have supported nine successful orbital-class launches. (Tom Cross & Pauline Acalin)

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Speaking at 2019’s Asia-Pacific Satellite (APSAT) Conference, SpaceX Vice President of Commercial Sales Jonathan Hofeller – squeezed into a sea of breaking-news updates – announced that the company plans to launch the same Falcon 9 Block 5 booster for the fifth (or sixth) time by the end of 2019.

Just an add-on at the end of a number of updates focused on SpaceX’s next-generation Starship/Super Heavy rocket, the phrasing reported by SpaceNews.com technically means that there are plans for a Falcon 9 booster to launch for the sixth time in the second half of 2019. The demonstration of such an extreme level of operational reusability barely 18 months after Falcon 9 Block 5’s debut would make it clear that SpaceX’s latest Falcon upgrade has been a resounding success. In line with those positive signs, Hofeller also noted that SpaceX is already starting to transfer the fruits of those labors to its customers by permanently lowering the base price of Falcon 9 launch contracts.

Most recently, SpaceX flew the same Falcon 9 booster for the third time (B1049) in support of its first dedicated Starlink launch, May 2019. (SpaceX/Teslarati)

Block 5 off to a spectacular start

First reported on by SpaceNews’ Caleb Henry, one of a few spaceflight journalists able to attend 2019’s Jakarta, Indonesia-based APSAT conference, details about the near-term future of Falcon 9 Block 5 reusability milestones were effectively tacked on at the end of much higher-profile breaking-news tidbits. Although wildly ambitious Starship goals led headlines (stay tuned for Teslarati’s own analysis later this week), the fact remains that ambitious development goals are inherently tenuous and likely to slip, particularly when the subject is large-scale, fully-reusable launch vehicles developed from a nearly blank slate.

What is not up for debate, however, is the fact that SpaceX’s Falcon 9 Block 5 upgrade is already flying routinely and reliably. After a successful debut in May 2018, Block 5 took over all SpaceX launches less than two months later. Since then, a total of 12 freshly-built Block 5 boosters have supported 16 Falcon 9 and 2 Falcon Heavy launches, ten – more than half – of which involved flight-proven boosters. According to official statements made recently by SpaceX executives, Block 5 boosters are expected to support an additional 12-19* launches in the second half of 2019.

*Derived by stacking “2-6 dedicated Starlink launches” and SpaceX’s 2019 target of 18-21 nonStarlink launches

Moving into 2019, SpaceX is likely just months away from its next triple and quadruple-reuse milestones.
Falcon 9 B1046 became the first SpaceX booster to launch three separate times in early-December 2018. (Pauline Acalin)

Tied directly to claims that the same Falcon 9 Block 5 booster will launch for the fifth or sixth time by the end of 2019, SpaceX already has three Falcon 9 boosters that have each completed a trio of launches, as well as an additional five with either one or two launches under their belts. Pictured at the top of the article, all three thrice-flown Falcon 9 boosters – B1046, B1048, and B1049 – could arguably be selected to become the next pathfinder as SpaceX prepares to put boosters through their fourth launches and beyond.

Rumored to be assigned to Crew Dragon’s in-flight abort (IFA) test prior to a major capsule anomaly on April 20th, B1046 could be off the manifest if SpaceX is confident that said IFA test can still be performed within the next several months. It’s currently unclear if that is a viable option for SpaceX’s Crew Dragon schedule, likely to remain uncertain until the failure investigation is fully completed and any necessary design/hardware/software fixes have been implemented. B1046 completed its third launch in December 2018 (a full six months ago), followed by B1048 in February 2019 and B1049 in May 2019. Although the “unknown territory” aspect of Block 5 reuse milestones is becoming less noteworthy, SpaceX is still likely to treat B104X’s fourth launch as a pathfinder, requiring extra time to dot I’s and cross T’s. With B1046 and B1048 potentially ready to go, that milestone could come any time now.

Falcon 9 B1046 lands aboard drone ship OCISLY after its third successful launch in December 2018, a reusability milestone for SpaceX. (SpaceX)

SpaceX customers already reaping financial benefits

Meanwhile, although certain heads-in-sand competitors continue to act and claim otherwise, SpaceX has reportedly normalized earlier prices for customers flying on flight-proven milestone missions. Speaking at APSAT, SpaceX’s Jonathan Hofeller indicated that that pricing is now the company’s “normal pricing”, pushing Falcon 9’s base price as low as ~$50M according to comments CEO Elon Musk made about a year ago. Two years prior to those comments and about six months prior to SpaceX’s first-ever booster reuse, COO and President Gwynne Shotwell reported that the company was offering discounts of ~10% for customers willing to contract launches on flight-proven Falcon 9 boosters.

In other words, SpaceX has cut Falcon 9’s base launch costs by anywhere from 10-20% over the last three years, a period in which the Falcon 9 V1.2 Full Thrust rocket’s capabilities were also dramatically upgraded from Block 1 (debut: December 2015) through Block 5 (debut: May 2018). Speaking during a press conference focused on Falcon 9 Block 5’s launch debut, CEO Elon Musk estimated that SpaceX has spent more than $1 billion to develop Falcon 9 reusability, while he previously estimated Falcon Heavy’s development costs to be well north of ~$500M. Musk and other execs have previously confirmed that SpaceX means to recoup some or all of that investment, indicating that the current margins of Falcon 9 launch contracts must be extremely favorable.

A remote camera set up by Teslarati photographer Pauline Acalin captured this incredible view of all 27 Merlin 1D engines powering Falcon Heavy’s first stage. (Pauline Acalin)

SpaceX has a healthy commercial manifest and will need to support dozens to hundreds of its own dedicated Starlink launches in order to orbit an operational and profitable constellation.

Check out Teslarati’s Marketplace! We offer Tesla accessories, including for the Tesla Cybertruck and Tesla Model 3.

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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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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