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A different angle of Falcon Heavy Flight 2's liftoff from Teslarati photographer Pauline Acalin. (Pauline Acalin) A different angle of Falcon Heavy Flight 2's liftoff from Teslarati photographer Pauline Acalin. (Pauline Acalin)

SpaceX

SpaceX preps for Cargo Dragon, Falcon Heavy launches despite setbacks

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Despite suffering the loss of the first Falcon Heavy Block 5 center core and a catastrophic failure of the first flight-proven Crew Dragon spacecraft in nearly the same week, SpaceX’s core operations continue as usual to prepare for multiple launches in the coming months.

The echoes of the past week’s failures and ‘anomalies’ will undoubtedly ring for months to come but SpaceX now finds itself in a unique situation. Despite the imminent start of a major failure investigation, it appears unlikely – at least for the time being – that it will impact the majority of Falcon 9 and Falcon Heavy launches planned for the rest of 2019. Currently on the Q2 2019 manifest are Cargo Dragon’s 17th operational mission (CRS-17), the first operational Starlink launch, Spacecom’s Amos-17 satellite, the Canadian Radarsat Constellation Mission (RCM), and Falcon Heavy’s third launch (STP-2).

Spotted on April 20th, this Falcon upper stage is most likely bound for the launch of either Starlink-1 or Amos-17.

Cargo Dragon – CRS-17

Following an April 20th explosion that destroyed Crew Dragon C201, SpaceX’s next launch – Cargo Dragon CRS-17 – has likely just become the most important in the near-term. Although Crew Dragon shares almost nothing directly in common with Cargo Dragon, both spacecraft still do come from the same lineage, relying on the same propellant and Draco maneuvering thrusters, as well as similar plumbing (excluding SuperDraco pods) and many of the same engineers and technicians.

On the other hand, Cargo Dragon has never suffered a catastrophic anomaly on the ground or in flight, although SpaceX has dealt with a fair share of less serious issues throughout the spacecraft’s operational life. Further, following the August 2017 launch of CRS-12, every CRS mission has launched with a flight-proven Cargo Dragon spacecraft. In fact, it’s quite likely that the CRS-12 Cargo Dragon capsule is the same spacecraft that has been refurbished for CRS-17, as it is currently the only flightworthy capsule to have only flown one orbital resupply mission.

It’s unclear which Falcon 9 booster has been assigned to CRS-17. NASA’s agreement with SpaceX for flight-proven boosters has been predicated on keeping those boosters ‘in-family’, so to speak, meaning that NASA will only accept flight-proven boosters if they have only flown NASA missions. The only booster that currently fits that bill is B1051, previously flown during Crew Dragon’s orbital launch debut on March 2nd, but B1051 has reportedly been assigned to SpaceX’s second Vandenberg launch of 2019 at the customer’s request. CRS-17 will thus likely launch on a new Falcon 9 booster (B1056). There is a chance that Crew Dragon’s catastrophic failure has severely contaminated the Landing Zone area with unburnt MMH and NTO, both of which are extraordinarily toxic to humans in even the tiniest of quantities.

Some launch-related questions may be answered in a NASA media briefing planned for 11am EDT, April 22nd. CRS-17 is scheduled to launch no earlier than 4:22 am EDT (08:22 UTC), April 30th.

Cargo Dragon capsule C113 and its expendable trunk depart the ISS after successfully completing CRS-12, September 2017. (NASA)
CRS-17’s fresh Cargo Dragon trunk is shown here with two major unpressurized payloads, the Orbiting Carbon Observatory 3 (OCO-3) and STP-H6, which will investigate communicating with X-rays, among other things. (SpaceX via NASA)

Starlink, Falcon Heavy, and more

Meanwhile, the Falcon upper/second stage (S2) spotted in the tweet at the top of the article serves as evidence of preparations for launches planned in May/June, as do a duo of first stage boosters spied during their own Cape Canaveral arrivals. All that’s missing to round out a busy week of SpaceX transportation is the appearance of one or several payload fairings, although CEO Elon Musk says that the company will try to reuse Falcon Heavy Flight 2’s fairing on the first Starlink launch.

Said Starlink launch – unofficially labeled Starlink-1 – is currently scheduled for liftoff no earlier than mid-May, likely making it the SpaceX mission that will follow CRS-17. The most likely Falcon 9 S1 candidate is the thrice-flown Block 5 booster B1046, a move that would retire risk otherwise transmitted to customers. SpaceX has now flown two separate Falcon 9 boosters (B1046 and B1048) three times without major issue, meaning that the fourth flight of the same booster (and beyond) will be new territory for reuse at some level.

B1046.3 landed aboard drone ship Just Read The Instructions after a successful third launch, December 2018. (SpaceX)
Falcon 9 B1048 returned to Port Canaveral on Feb. 24 after the rocket’s own third successful launch and landing. (Tom Cross)

Beyond Starlink-1, SpaceX has the communications satellite Amos-17 and Radarsat Constellation Mission (RCM), both of which are understood to be targeting launch no earlier than (NET) early June. Finally, Falcon Heavy Flight 3 – carrying the US Air Force’s STP-2 mission – is scheduled to launch NET June 22nd, although some additional delays are probable.

From a business-as-usual perspective, the fact that Crew Dragon C201 failed during intentional testing on the ground means that it will likely be SpaceX’s least commercially disruptive failure yet. This could change for any number of reasons, depending on the conclusions drawn by the joint NASA-SpaceX investigation soon to begin, and it’s far too early to draw far-reaching conclusions. Chances are good that the impact to non-Crew Dragon launches will be minimal but only time will tell as SpaceX begins to quite literally pick up the pieces and start a deep-dive analysis of all data gathered from Saturday’s failure.

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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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Elon Musk

SpaceX’s next Starship launch is about to attempt its biggest leap yet

SpaceX targets September 22 for Starship Flight 14, its first attempt to reach real orbit.

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SpaceX has set September 22 as the target date for Starship’s 14th test flight, and this one carries a different goal than any of the 13 that came before it. Every previous Starship mission has intentionally flown a suborbital arc, reentering the atmosphere within the same hour it launched. Flight 14 is designed to send the craft into a genuine orbit around Earth for the first time.

The launch window opens at 7:15 a.m. Central time at Starbase in South Texas and runs for 75 minutes, pending regulatory approval, according to SpaceX’s mission description published Tuesday. If the flight goes as planned, Starship will circle the planet roughly six times at an altitude near 275 kilometers over about ten hours before a deorbit burn sends it toward a splashdown in the Pacific Ocean west of Chile, a departure from the Indian Ocean recoveries used on the last several flights.

The mission also marks the first attempt to put a working batch of Starlink V3 satellites into actual service. Flight 13 carried 20 of the new satellites in July, but because that mission never left a suborbital trajectory, the payload reentered along with the ship instead of separating into orbit.

SpaceX tells the FCC that Starship Flight 14 is going to orbit

Each V3 satellite is rated for roughly one terabit per second of downlink capacity, so a successful deployment on Flight 14 would be SpaceX’s largest single jump in network bandwidth since Starlink began flying on Falcon 9.

Flight 13 still did the heavier lifting on the technical side. That July mission flew a deliberately more stressful reentry profile to test Starship’s heat shield, and the ship survived its softest splashdown yet, intact enough for drone inspections shortly after landing. Elon Musk said the flight delivered “all the heat shield data we needed and then some,” a result Teslarati covered in detail when he later said SpaceX had solved the vehicle’s biggest reusability challenge. Flight 14 is where SpaceX starts spending that confidence on an actual orbital insertion rather than another controlled fall back to Earth.

One thing Flight 14 will not attempt is a tower catch of the ship. Musk floated the idea right after Flight 13, but walked the timeline back in August, saying a catch attempt was more likely “in a few months.” The Super Heavy booster will still aim for its own recovery, targeting an offshore landing point in the Gulf of America, the same approach used on recent flights.

September 22 is SpaceX’s own target, not a locked date. Starship’s schedule has slipped before over hardware readiness and FAA sign off, and the company has said as much in its own mission notes. But the plan itself represents the clearest marker yet that Starship is moving from a suborbital test program into something meant to carry paying payloads and, eventually, people.

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