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SpaceX's workhorse rocket is almost halfway to reaching ambitious reusability goals
Thanks to a recent cluster of major milestones, SpaceX’s family of Falcon 9 and Heavy rockets are rapidly nearing the halfway point along the path to several ambitious goals for booster and fairing reusability.
Back in the early 2010s, SpaceX’s CEO Elon Musk’s original dream was to make Falcon 9 and Falcon Heavy 100% reusable, meaning that the company would need to find ways to reliably recover boosters (first stages), payload fairings (or Dragon spacecraft), and the rocket’s upper (second) stages. The concept of Falcon 9 second stage reuse actually survived all the way into 2018 before Musk ultimately conceded defeat, accepting that Falcon 9 and Heavy simply didn’t offer the performance necessary to make full reusability a worthwhile investment. The concept, however, still lives on in SpaceX’s next-generation Starship launch vehicle.
This does mean Falcon rockets will never be fully reusable, but it’s still up to SpaceX to decide how far they’ll push the envelope with the rockets’ existing reusable hardware. At the moment, it appears that a vast majority of Falcon rockets will be able to be routinely recovered and reused, capitalizing on the fact that Falcon 9 and Falcon Heavy boosters already represent some 50-75% of the cost of building each two-stage rocket. While Falcon upper stages and Dragon trunks will never be reused, both booster and payload fairing reuse are rapidly approaching their own unique halfway points on the path to ambitious reusability targets.
Shortly after SpaceX’s January 29th Starlink V1 L3 launch, carrying the third batch of 60 upgraded v1.0 satellites to orbit, twin fairing recovery ships GO Ms. Tree (formerly Mr. Steven) and Ms. Chief teamed up for their second-ever simultaneous fairing catch attempt. Ms. Chief – only active since November 2019 – reportedly just barely missed her first successful catch, while Ms. Tree managed to snag one of the Falcon 9 fairing halves in her massive net – the ship’s third successful catch.
Worth an estimated $3M per half according to CEO Elon Musk, Falcon 9’s payload fairing represents approximately 10% of the rocket’s total manufacturing cost. Made out of a carbon fiber and aluminum honeycomb composite material, fairings also also takes a disproportionate amount of time and space to produce – primarily due to their large size (a school bus could comfortably fit inside a fairing) and the need for commensurately large curing ovens. That composite honeycomb structure also makes it relatively easy for Falcon payload fairings to suffer from corrosion when dunked in seawater, leading SpaceX to the seemingly bizarre solution of installing giant arms and nets on ships.
Catching fairings has proven to be incredibly unforgiving, however, and SpaceX has simultaneously worked to make its Falcon fairings much more waterproof (and thus resistant to corrosion) while keeping them as light as possible. In fact, SpaceX’s first fairing reuse occurred less than three months ago and used two halves that previously landed in the Atlantic Ocean, demonstrating that difficulties reliably catching fairings will not stand in the way of reuse.
Ms. Chief missed her January 29th catch attempt, she still managed to fish her fairing half out of the ocean, while Ms. Tree’s successfully-caught half means that SpaceX ultimately recovered the full Starlink V1 L3 fairing. With a little luck, that recovered fairing will launch again in the near future.
Five for 5
Simultaneously, SpaceX is making excellent progress along the path to airliner-like rocket reusability. In November 2019, on the same Starlink mission that debuted flight-proven fairings, Falcon 9 booster B1048 became the first SpaceX rocket to launch (and land) four times. Less than two months later, Falcon 9 B1049 doubled down on that reusability milestone, becoming the second booster to launch and land four times, followed by Falcon 9 B1046 just 12 days later. Falcon 9 B1046 was (intentionally) destroyed after its fourth launch, precluding a fourth landing attempt, but it emphasizes just how confident SpaceX is in Falcon 9’s Block 5 upgrade.
Designed to allow each Falcon 9 and Heavy booster to perform a minimum of 10 launches and landings, the Block 5 upgrade is potentially just a few weeks away from reaching the halfway point along the path to that ambitious reusability design goal. Speaking at the NASA Kennedy Space Center earlier this month, a SpaceX engineer recently revealed that a Falcon 9 booster would conduct its fifth launch in support of a Starlink mission (either Starlink V1 L4 or L5) scheduled no earlier than (NET) mid-to-late February.
Pictured above, Falcon 9 booster B1048 – the first to launch four times – is the likeliest candidate for the first fifth flight of a SpaceX rocket. If the booster’s reuse goes as planned, it’s safe to say that Falcon 9 B1049.4 will follow closely on the heels of its predecessor with its own fifth-flight milestone. All things considered, SpaceX’s workhorse rocket is rapidly approaching the zenith of its theoretically-achievable reusability.
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Armored Tesla Cybertruck “War Machine” debuts at Defense Expo 2025
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Tesla Megapacks chosen for 548 MWh energy storage project in Japan
Tesla plans to supply over 100 Megapack units to support a large stationary storage project in Japan, making it one of the country’s largest energy storage facilities.
Tesla’s Megapack grid-scale batteries have been selected to back an energy storage project in Japan, coming as the latest of the company’s continued deployment of the hardware.
As detailed in a report from Nikkei this week, Tesla plans to supply 142 Megapack units to support a 548 MWh storage project in Japan, set to become one of the country’s largest energy storage facilities. The project is being overseen by financial firm Orix, and it will be located at a facility Maibara in central Japan’s Shiga prefecture, and it aims to come online in early 2027.
The deal is just the latest of several Megapack deployments over the past few years, as the company continues to ramp production of the units. Tesla currently produces the Megapack at a facility in Lathrop, California, though the company also recently completed construction on its second so-called “Megafactory” in Shanghai China and is expected to begin production in the coming weeks.
READ MORE ON TESLA MEGAPACKS: Tesla Megapacks help power battery supplier Panasonic’s Kyoto test site
Tesla’s production of the Megapack has been ramping up at the Lathrop facility since initially opening in 2022, and both this site and the Shanghai Megafactory are aiming to eventually reach a volume production of 10,000 Megapack units per year. The company surpassed its 10,000th Megapack unit produced at Lathrop in November.
During Tesla’s Q4 earnings call last week, CEO Elon Musk also said that the company is looking to construct a third Megafactory, though he did not disclose where.
Last year, Tesla Energy also had record deployments of its Megapack and Powerwall home batteries with a total of 31.4 GWh of energy products deployed for a 114-percent increase from 2023.
Other recently deployed or announced Megapack projects include a massive 600 MW/1,600 MWh facility in Melbourne, a 75 MW/300 MWh energy storage site in Belgium, and a 228 MW/912 MWh storage project in Chile, along with many others still.
What are your thoughts? Let me know at zach@teslarati.com, find me on X at @zacharyvisconti, or send us tips at tips@teslarati.com.
Tesla highlights the Megapack site replacing Hawaii’s last coal plant
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Elon Musk responds to Ontario canceling $100M Starlink deal amid tariff drama
Ontario Premier Doug Ford said, opens new tab on February 3 that he was “ripping up” his province’s CA$100 million agreement with Starlink in response to the U.S. imposing tariffs on Canadian goods.
Elon Musk company SpaceX is set to lose a $100 million deal with the Canadian province of Ontario following a response to the Trump administration’s decision to apply 25 percent tariffs to the country.
Starlink, a satellite-based internet service launched by the Musk entity SpaceX, will lose a $100 million deal it had with Ontario, Premier Doug Ford announced today.
Starting today and until U.S. tariffs are removed, Ontario is banning American companies from provincial contracts.
Every year, the Ontario government and its agencies spend $30 billion on procurement, alongside our $200 billion plan to build Ontario. U.S.-based businesses will…
— Doug Ford (@fordnation) February 3, 2025
Ford said on X today that Ontario is banning American companies from provincial contracts:
“We’ll be ripping up the province’s contract with Starlink. Ontario won’t do business with people hellbent on destroying our economy. Canada didn’t start this fight with the U.S., but you better believe we’re ready to win it.”
It is a blow to the citizens of the province more than anything, as the Starlink internet constellation has provided people in rural areas across the globe stable and reliable access for several years.
Musk responded in simple terms, stating, “Oh well.”
Oh well https://t.co/1jpMu55T6s
— Elon Musk (@elonmusk) February 3, 2025
It seems Musk is less than enthused about the fact that Starlink is being eliminated from the province, but it does not seem like all that big of a blow either.
As previously mentioned, this impacts citizens more than Starlink itself, which has established itself as a main player in reliable internet access. Starlink has signed several contracts with various airlines and maritime companies.
It is also expanding to new territories across the globe on an almost daily basis.
With Mexico already working to avoid the tariff situation with the United States, it will be interesting to see if Canada does the same.
The two have shared a pleasant relationship, but President Trump is putting his foot down in terms of what comes across the border, which could impact Americans in the short term.
Armored Tesla Cybertruck “War Machine” debuts at Defense Expo 2025
Tesla Megapacks chosen for 548 MWh energy storage project in Japan
