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SpaceX will transition all launches to Falcon 9 Block 5 rockets after next mission
SpaceX’s 13th reuse of a Falcon 9 booster marked the second-to-last orbital mission of older boosters before the rocket’s highly reusable Block 5 upgrade takes over all future commercial launches.
If only for the staggering rise of SpaceX’s program of reusable rockets, June 4’s Falcon 9 launch was novel and thrilling in part because its flight-proven booster was intentionally stripped of all reuse-related hardware to bestow as much performance as possible on the mission’s large geostationary communications satellite payload, named SES-12. While this practice of intentionally expending non-Block 5 flight-proven boosters after launch has actually been fairly common over the course of the last seven Falcon 9 reflights, excluding Falcon Heavy – SpaceX is, in essence, betting heavily on the viability and success of the rocket’s quasi-final Block 5 upgrade.
SpaceX’s second to last commercial launch with a non-Block 5 Falcon 9 was completed around 1 am EST June 4. It’s once flight-proven booster ended its life in the Atlantic soon after liftoff. (Tom Cross)
Following June 4’s SES-12 launch, after which Falcon 9 S1 (B1040, previously flown on the September 2017 launch of a classified X-37B spaceplane) arced down its final parabola into the Atlantic, SpaceX has just a single commercial launch of a Block 4 booster scheduled. In fact, that launch happens to be next up on the company’s manifest: currently no earlier than (NET) June 28, CRS-15 will see the same booster (B1045) that launched NASA’s TESS exoplanet observatory scarcely ten weeks prior send a refurbished Cargo Dragon to the International Space Station. After CRS-15, which will also see its booster expended in the Atlantic, just one flightworthy Block 4 rocket will remain in SpaceX’s fleet, and that Falcon 9 booster is understood to be undergoing refurbishment for its final reflight. That mission, however, is a suborbital demonstration designed to prove that SpaceX’s Crew Dragon spacecraft can wrest its human passengers out of harm’s way in the event of a launch vehicle failure during flight (SpaceX already proved it can accomplish the same task while the rocket is still on the launch pad in a 2015 demo).
https://twitter.com/_TomCross_/status/1003509362906853376
No turning back now
While a critical path for SpaceX’s future of reliably delivering crew to orbit, its suborbital nature makes categorically distinct from past and future Falcon launches, all of which have been conducted with the intent of placing payload(s) into Earth orbit. Thus we arrive back at B1045 and CRS-15, currently scheduled as both SpaceX’s next launch and the final orbital mission before Falcon 9/Heavy Block 5 becomes the company’s only operational route to space for at least the next two years, give or take half a year. It’s thus somewhat poetic that the booster tasked with CRS-15 will easily smash SpaceX’s previous record for refurbishment (135 days) by almost a factor of two, going from drone ship recovery to reflight in as few as 71 days. Whatever it becomes, that refurbishment record will likely be broken by the first Block 5 reflight, a trend that will almost certainly continue until SpaceX reaches Musk’s fabled 24-hour turnaround, perhaps before the end of next year.
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- A flight-proven Falcon 9, B1040, looking particularly well-done before its second and final launch on June 4. (Tom Cross)
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- SES-12’s Block 4 booster roars into the air on its final flight. (SpaceX)
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- Falcon 9 Block 5 completed its first launch on May 11, carrying the Bangabandhu-1 communications satellite to geostationary transfer orbit. (Tom Cross)
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- It may not immediately look like a major departure from past versions, but Block 5 could theoretically usher in 10-100 reflights of a single rocket booster. (SpaceX)
Extrapolating from the launch company’s recent history, the culmination of CRS-15 will potentially leave SpaceX with as few as two Falcon 9 Block 5 boosters as its entire flight-ready rocket fleet, despite anywhere from 12 to 16 launches remaining on the second half of the company’s 2018 manifest. Currently standing at six boosters produced in 2018, roughly eight to be completed before the end of the year per COO and President Gwynne Shotwell (in this case likely boosters B1048-1056), an achievement that would grow the ranks of the company’s fleet of new Block 5 boosters to ten total. But, assuming a core is delivered from the Hawthorne factory every month, SpaceX will need to reuse Block 5 boosters as early as July to prevent considerable delays to their 2018 manifest, delays that would undoubtedly push multiple missions into 2019.
Here’s to hoping that the Block 5 upgrade is as incredible of a success as SpaceX has designed it to be. Follow the Teslarati team for real-time updates, glimpses behind the scenes, and photos from Teslarati’s East and West Coast photographers.
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News
SpaceX just locked up a NASA record no other U.S. spacecraft can touch
SpaceX’s Crew-13 Dragon reached the ISS in under eight hours, and NASA confirmed a record.
SpaceX now owns every spot on the list of the five fastest trips a U.S. spacecraft has ever made to the International Space Station, and its newest entry beat the old mark by more than four hours.
Crew Dragon Grace docked to the forward port of the station’s Harmony module at 7:05 p.m. ET on October 1, just 7 hours and 55 minutes after lifting off from Space Launch Complex 40 at Cape Canaveral. NASA confirmed the milestone in a space station blog update, writing that the flight “marked the fastest launch‑to‑docking of a U.S. spacecraft in the history of the International Space Station.”
The previous U.S. record also belonged to Dragon. SpaceX’s uncrewed CRS-31 cargo mission reached the station in a little over 12 hours in November 2024. The fastest crewed trip before last week was Crew-11, which took 14 hours and 43 minutes in August 2025, according to Space.com.
A post that Elon Musk reposted on Monday filled out the rest of the ranking. Behind Crew-13, CRS-31 and Crew-11 sit Axiom’s Ax-2 mission at 15 hours and 35 minutes and NASA’s Crew-4 at 15 hours and 44 minutes. All five flew on Dragon.
SpaceX turned a heralding moment for Starship into its greatest
Crew-13 carried NASA astronauts Jessica Watkins and Luke Delaney, Canadian Space Agency astronaut Joshua Kutryk, and Roscosmos cosmonaut Sergey Teteryatnikov. NASA had projected a docking around 8 p.m. ET, as Teslarati reported the day before launch, and Dragon arrived nearly an hour early. Our launch day coverage noted that the flight was lined up to be the quickest Crew Dragon transit yet.
The speed came from timing more than hardware. SpaceX’s Julianna Scheiman said the station “was in an opportune spot in space,” which let Dragon start closing the gap almost immediately after reaching orbit. “This is close to the fastest it could be,” she added. Most Crew Dragon flights still take close to a day, using a series of Draco thruster burns to raise and phase their orbit before arrival.
Dragon’s next job at the station is a departure. NASA said Monday it is targeting 8:05 a.m. ET on Wednesday, October 7, for Crew-12 to undock, setting up a splashdown off the coast of California around 11:34 a.m. on Thursday. Clearing that port makes room for CRS-35, a cargo Dragon carrying the final set of iROSA solar arrays.
Dragon remains NASA’s only operational ride to the station while Boeing’s Starliner stays grounded, and the agency recently added Crew-15, Crew-16 and Crew-17 to SpaceX’s contract in a $946 million modification.
Elon Musk has acknowledged that early discussions with Taiwan Semiconductor Manufacturing Company (TSMC) could bring the company into his ambitious Terafab semiconductor project, signaling a possible partnership with the world’s leading contract chipmaker.
Musk confirmed that early talks are underway, but as of right now, they are “just discussions.” There is no confirmation of a deal nor dismissal of the possibility of one, leaving open the prospect of one of the largest advanced-chip collaborations under discussion in the U.S.
@wholemars Just discussions, but something may come of it
— Elon Musk (@elonmusk) October 3, 2026
The report that speculated on potential discussions between Terafab and TSMC comes from Tim Culpan, who outlined a few ways the collaboration could operate. One is TSMC using the project as an “anchor customer” for future facilities in Texas, potentially contributing process expertise, operational know-how, or capacity while Terafab provides capital, long-term purchase commitments, or both.
Tesla and SpaceX jointly developed the Terafab project, with Intel already participating on the tech side. Elon Musk announced the project in March, and it intends to produce more than one terawatt of AI compute capacity annually once fully built.
Company statements place the first phase at approximately $16.8 billion in cost, with later filings pointing to a total that could reach well into the tens of billions across multiple stages.
Intel joined the effort in April 2026 and is expected to supply its 14A manufacturing process for the full-scale plant.
Musk has said existing suppliers, including Samsung and TSMC, remain important for near-term needs; Tesla already has production arrangements with Samsung for AI5 and AI6 chips, but that future demand from Optimus robots, Cybercab vehicles, and planned space-based data centers will eventually exceed what the global industry can currently deliver.
Terafab is positioned as the long-term answer to that projected shortfall, and Tesla did something similar during COVID to avoid a chip shortage. This is just a much larger-scale solution.
If the partnership were to materialize, it would add TSMC’s industry-leading strategies to a project that already combines Tesla’s and SpaceX’s capital and offtake with Intel’s process technology. For now, the only public confirmation is Musk’s brief acknowledgement that conversations are occurring.
Tesla’s early strategy for charging units operating within its Robotaxi fleet reveals that the company surely has not lost any of that scrappy DNA that took it from an unlikely success story to the most valuable carmaker in the world.
An observer at a Tesla Supercharger in Austin spotted ten total Robotaxi vehicles arrive: one Cybercab and nine Model Y units. A Tesla employee was waiting at the lot and allowed each unit to park itself; every car that arrived had nobody in it.
Tesla wins FCC approval for wireless Cybercab charging system
The Tesla employee would walk around and plug each car in, adjusting the parking if needed:
So look at what I found. This is how Tesla charges unsupervised robotaxis at a public supercharger. Here is a driverless Cybercab showing up with no one in it. There are 9 other Model Ys that showed up too. A Tesla employee is walking around and plugging each of them in. She also moves the cars if they are not positioned well enough to charge. I love this process. One person charges multiple robotaxis at once
— Abhimanyu Yadav (@WorldlyReviewer) October 3, 2026
It’s a very interesting strategy, but extremely understandable at this early point in the Robotaxi program. It’s only been out for about 15 months, and Cybercab just entered the fleet in early September.
On top of that, Tesla is still working tirelessly on its wireless charging apparatus, and a new patent was just published regarding that product last week.
However, this is just another example of how Tesla still has plenty of that scrappy DNA leftover from the “production hell” days, when CEO Elon Musk slept on the floor of the factory, employees were working crazy hours, Tesla was building Sprung Structures to build cars in, and the company was tiptoeing on the brink of bankruptcy.
@Teslarati Sheer magnitude of the entire production system is hard to appreciate. Almost every element of production is >75% automated. Only wire harnesses & general assembly, which are <10% of production costs, are primarily manual.
— Elon Musk (@elonmusk) October 12, 2020
For now, Tesla is utilizing a simple system for recharging its ride-hailing vehicles, and that is a Tesla employee doing it manually until another solution presents itself. Sure, it’s not the most high-tech thing, and it certainly is not what people might have expected at this point in time, but it works, and it’s keeping the entire suite running.
SpaceX just locked up a NASA record no other U.S. spacecraft can touch
Elon Musk teases TSMC as potential Terafab partner
