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US Air Force issues RFP for massive rockets, SpaceX’s BFR could be one of them

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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.

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.

 

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.

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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.

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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Elon Musk

Tesla’s mysterious Robovan makes a sneak peek with Optimus in Terafab video

Elon Musk shared a new Terafab video showing Optimus, Robovans, and a stunningly futuristic campus.

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SpaceX Terafab rendering

Elon Musk posted a new video of Terafab on X Thursday morning, and the most eye-catching details in it were not the building itself, but two products still awaiting production: Optimus and the Robovan.

The concept render, credited to SpaceX, shows Optimus robots working the grounds of the roughly 2.5-mile-long facility planned for the Gibbons Creek site in Grimes County, while a Robovan glides along an elevated roadway cutting through the building itself, sharing the frame with a Tesla Semi and a Cybercab.

Robovan is the boxy, driverless people and cargo mover Musk unveiled alongside Cybercab at Tesla’s “We, Robot” event in October 2024. He pitched it as a way to move up to 20 passengers at once, or handle freight instead, at a target cost he claimed could fall under a dollar a mile, with no steering wheel or pedals, the same layout as Cybercab. Nearly two years later, Robovan still has no confirmed production timeline and has not shown up in any factory footage, which makes Thursday’s render one of the only recent looks at the vehicle in any form.

Optimus has moved further along. Tesla began converting Fremont’s old Model S and Model X assembly line into a Gen 3 Optimus production line earlier this year, and Musk visited the site on July 1 to mark the changeover. A second, larger Optimus plant is under construction at Giga Texas, targeting volume production in summer 2027 and eventual capacity of 10 million units a year. Tesla AI lead Ashok Elluswamy said this month the robot has “big shoes to fill” in replacing the S and X line, while Musk has repeatedly called Optimus the company’s biggest product of any kind, with a long-term price he has pegged between $20,000 and $30,000.

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“Terafab Texas will be the largest and most valuable building on Earth by far,” Musk wrote alongside the clip. “And it will be stunningly beautiful.”

One quote post summed up the reaction: “Futuristic scene with RoboVan + Cybercab + Tesla Semi + Optimus.”

Beyond the vehicles, the architecture wrapped around them stands out too. The building’s facade is canted at sharp angles, with illuminated horizontal bands running through what appears to be a multi level interior visible from outside. Below the elevated roadway, pedestrians walk along a plaza next to a reflecting pool, and the skyline behind the campus is dotted with angular spires that read more like sculpture than infrastructure, a departure from the strictly utilitarian look of Gigafactory Texas or Starbase.

The timing tracks with what Terafab representative Riley Trennell told Grimes County residents on Wednesday, when he said renderings of the facility would be released “within days.” Musk’s post followed less than 24 hours later, and Texas Governor Greg Abbott’s office sent out its own release Thursday confirming the project. As Teslarati reported this morning, Terafab’s tax abatement agreements with Grimes County are now signed and active, and SpaceX has sent the county its first $10 million payment under that deal. The dollar figure tied to this phase of construction, per Reuters, is $16.8 billion, one of the first hard capital expenditure numbers attached to Terafab since Musk unveiled the joint Tesla-SpaceX-xAI venture in March.Reaction on X ranged from enthusiastic to skeptical. “God Bless Texas! Everything is bigger and better in Texas!” one reply read. Another was more measured: “Terafab in a decade…..”

Whether the finished building matches the render is a separate question from whether Musk wanted people talking about the render itself. Less than a day after posting, the video had already crossed 5.5 million views.

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Cybertruck

Tesla Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

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The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Elon Musk

Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

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SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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