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SpaceX wins US Air Force contract for Falcon Heavy launch

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In an unexpected bode of confidence in the nascent vehicle, SpaceX has competed for and won a $130 million US Air Force launch contract for the massive Falcon Heavy rocket. While not planned to occur until September 2020 at the earliest, the most critical aspect of this development is the fact that the USAF has apparently already certified Falcon Heavy for high-value military launches.

The almost knee-jerk certification of Falcon Heavy for USAF launches makes for an extraordinary contrast when compared with the certification of SpaceX’s Falcon 9 workhorse rocket, a tedious political minefield that took more than two years, led SpaceX to (successfully) sue the federal government, and forced the Air Force to critically reexamine its internal processes after they delayed SpaceX’s certification by six or more months. For that particular endeavor, the USAF required SpaceX to complete three successful Falcon 9 launches, while also preventing SpaceX from engaging in launch contract competitions until their launch vehicle was certified in May 2015.

Jump ahead to 2018 and SpaceX appears to have been allowed to compete for this particular mission – known cryptically as AFSPC-52 – before Falcon Heavy had so much as completed an integrated static fire test. The awe-inspiring rocket did, however, complete a nearly-flawless debut launch in February 2018, a mission that required the company’s Falcon upper stage to survive a lengthy (6+ hour) coast in orbit before igniting its Merlin vacuum engine for one final burn. Regardless of the specifics, many of which have likely been kept under wraps, the Air Force must have been quite impressed with the rocket’s debut performance, and Falcon Heavy has now – according to President and COO Gwynne Shotwell – been certified for USAF missions just four months later.

 

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It’s somewhere between difficult and impossible to accurately compare the different payloads and launches of the Air Force Space Command (AFSPC), but SpaceX’s only competitor ULA was awarded a contract for the launch of two relatively different AFSPC payloads at an average (fixed) cost of $175 million per mission. Those satellites were likely much smaller than AFSPC-52 but they require direct insertion into geostationary orbit (GEO), whereas AFSPC-52 may instead be sent to a geostationary transfer orbit (GTO) before circularizing the orbit under its own power.

Still, SpaceX’s triple-booster Falcon Heavy launch contract will cost the USAF a slim $130m. It’s worth noting that the 2018 AFSPC-8 and -12 contracts awarded to ULA were for the company’s single-booster Atlas 5 rocket, with most of the draw coming from its admittedly advanced, efficient, and extraordinarily reliable Centaur upper stage, tasked with reigniting repeatedly to circularize the orbit of its valuable satellite payloads once in space.

While it requires far less rigor than the Air Force’s more secretive, national security-sensitive satellite launches, SpaceX’s second Falcon Heavy launchthis time with three highly-reusable Block 5 boosters – will also be conducted with the military branch as the primary customer. Known as Space Test Mission-2 (STP-2), Falcon Heavy will be tasked with carrying a stack of dozens of different smallsats to a variety of orbits. Of note, the vast majority of that mission’s payload comes in the form of a 5000-kilogram ballast mass, included because the mission was manifested on Falcon Heavy (instead of the operational Falcon 9) for the sole purpose of facilitating the rocket’s rapid certification for critical Air Force missions.

 

STP-2 is currently scheduled for no earlier than (NET) November 2018, while the third launch of Falcon Heavy – the commercial Arabsat 6A communications satellite – is tentatively targeted for December, although it’s almost guaranteed to slip into Q1 2019.

Follow us for live updates, peeks behind the scenes, and photos from Teslarati’s East and West coast photographers.

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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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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.

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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.

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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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