> None of the heat shields so far looked reusable without refurbishment, including this one.

What about this one looks not reusable without refurbishment?

To my eye it’s by far the best we’ve seen, no burn through on flaps, etc

Lots of missing tiles still. Best case is it's all infant mortality and replacing just those tiles will result in a durable heat shield for many more flights. Worst case is every flight loses that many tiles and the ablative underneath can't be reflown until replacement.

I wouldn't be surprised if we end up seeing a heat shield refurbishment attachment to the launch tower that allows technicians to access the side of the ship to patch up between flights without leaving the pad. They're going to need some kind of solution for the many back-to-back HLS refueling flights.