News
US Air Force issues RFP for massive rockets, SpaceX’s BFR could be one of them
The US Air Force has released a Request For Proposal (RFP) that hopes to fund the development of multiple heavy-lift rocket prototypes to launch no later than 2021. The USAF specified on October 5 that it wants to partially fund prototype development for at least three promising US-sourced launch vehicles, while maintaining the options to select none of the proposals or even more than three. The purpose of these broad strokes is to provide the Air Force and US military in general redundant access to space by way of “at least two domestic…launch service providers” capable of meeting National Security Space (NSS) requirements.
However unlikely it may seem, NASA experienced this firsthand when two of the vehicles it funded, SpaceX’s Falcon 9 and Orbital-ATK’s Antares, experienced complete failures within less than a year of each other. Both vehicle failures destroyed supplies intended for the International Space Station and forced NASA to rely on Soyuz missions to fill the gaps created while producing considerable uncertainty for the agency. By funding two or more independent launch vehicles, the Air Force would lessen the impact of such failures, and this assured access is rightly perceived as an invaluable commodity in the military.
- .While SpaceX’s own visualizations are gorgeous and thrilling in their own rights, Romax’s interpretation adds an unparalleled level of shock and awe. (SpaceX)
- A render of Blue Origin’s larger New Glenn vehicle. (Blue Origin)
- The only current render of OATK’s Next Generation Launcher. (OATK)
Several details in the latest proposal make it relatively easy to name the obvious prospective applicants. The payload requirements necessitate heavy lift or even super-heavy lift launch vehicles capable of placing anywhere from 5,000 to 37,500 pounds into a variety of Earth orbits, ranging from low Earth orbit (~500 mi) to direct transfer geostationary orbits (~19,200 mi). This narrows the field considerably, pushing out all smaller-scale vehicles. Also telling is a requirement that proposed launch vehicles make use of rocket propulsion systems (RPS) already funded for development by the USAF if at all possible.
Considering the inherently complex and difficult process of developing massive rockets, initial launch dates no later than 2021 (or 2024) likely mean that the vehicles being considered must already be under some level of serious development. This leaves us with four possible options in the US, undoubtedly not a coincidence given the RFP’s explicit goal of facilitating the creation of “at least three…prototypes as early as possible” and “at least two domestic…launch service providers”. These four vehicles are SpaceX’s BFR, Blue Origin’s New Glenn, ULA’s Vulcan, and Orbital-ATK’s NGL, all of which already have tentative inaugural launch dates clustered from 2019 to 2022. Perhaps even more revealing, all four vehicles can be expected to utilize several rocket propulsion systems (rocket engines) already funded by the Air Force, namely SpaceX’s Raptor, Blue Origin’s BE-4 and BE-3U, and Aerojet-Rocketdyne’s AR-1.
While the development of BE-4 and AR-1 have been somewhat veiled, SpaceX’s Raptor engine has publicly made a great deal of progress. As discussed during Elon Musk’s IAC 2017 presentation, the company has conducted an array of successful tests with its subscale Raptor program, to the tune of 42 individual hot-fire tests totaling more than 1,200 seconds. Musk also reported that the only thing preventing tests longer than 100 seconds was the size of the propellant tanks at the test stand, a genuinely impressive accomplishment if true. The sticking point, however, is how much difficulty SpaceX will have as they transfer to full-scale Raptor testing. The subscale Raptors being tested have a reported thrust of 1,000 kN, whereas the new full-scale thrust targets for BFR have settled on 1,700-1,900 kN, considerably smaller than the 3,000 kN figure from 2016 but still nearly a factor of two larger than the test articles SpaceX has had success with. In fact, educated speculation from SpaceX fans suggest that the operational Raptor as shown in 2017 may only need to be about 15% larger than the current test article(s). The pressure the full-size engine operates at will be considerably higher, so SpaceX’s work is not done by any means, but the company’s next-gen rocket propulsion system is arguably far closer to completion than any of its competitors’ offerings.
- SpaceX’s subscale Raptor engine has completed more than 1200 seconds of testing in less than two years. (SpaceX)
- A subscale version of BE-4 testing staged combustion and nozzle technology. (Blue Origin)
- Aerojet-Rocketdyne’s AR-1 preburner conducted its first successful test earlier this year. (AR)
As far as we are publicly aware, SpaceX’s subscale Raptor testing has yet to result in a major failure and has largely been a great success. Blue Origin’s BE-4 is known to have experienced at least one critical failure during hot-fire testing, while AR-1 has not yet begun full engine tests but is well into concrete hardware testing. Blue Origin’ s BE-4 engine and its New Glenn rocket are currently expected to fly for the first time before 2020, with AR’s NGL tentatively planning for a 2021 inaugural flight, assuming the company chooses to continue pursuing its development.
SpaceX has not yet specified when BFR or BFS will first take flight. Raptor is likely to begin full-scale testing relatively soon, and Musk revealed that SpaceX was aiming to begin construction of the first BFR as early as Q2 of 2018. It’s quickly starting to look like the U.S. is about to enter a sort of modern commercial space race and regardless of the outcome, the next several months and years are bound to be tense and exciting for SpaceX, Blue Origin, and the established incumbents as they battle for both public and private contracts.
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.
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.
The Giga Texas Optimus Factory latest update … construction keeps moving fast!
Steel assembly is now only about 5 column grids from the north perimeter beam. Concrete is going in on the three upper floors, rebar is still being laid for more pours, and footing / grade-beam work… pic.twitter.com/qvFPvwnYzW
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) September 17, 2026
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.
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.
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.
News
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.
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.





