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SpaceX, NASA practice astronaut recovery ahead of Crew Dragon’s crewed launch debut

On August 13th and 15th, SpaceX and NASA teams completed several critical Crew Dragon-related rehearsals, practicing methods of safely extracting astronauts from the capsule and evacuating them to land-based medical facilities via helicopter. (NASA)

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SpaceX and NASA teams continue to prepare for Crew Dragon’s inaugural crewed launch (Demo-2) to the International Space Station (ISS) slated to possibly – but not likely – occur by year’s end.

On Tuesday, an official NASA Twitter account published images of teams from SpaceX and the space agency performing a full rehearsal of crew recovery and extraction procedures, including the duo of NASA astronauts scheduled to fly first on SpaceX’s next-generation spacecraft.

The rehearsal took place at the Trident Basin in Cape Canaveral, Florida aboard GO Searcher, one of two East Coast recovery vessels SpaceX uses for Crew Dragon recoveries.

NASA astronauts Bob Behnken, left, and Doug Hurley board the SpaceX GO Searcher ship at the Trident Basin in Cape Canaveral, Florida, on August 13, 2019 to rehearse extracting astronauts from SpaceX’s Crew Dragon. (NASA/Bill Ingalls)

A high-fidelity mockup of Crew Dragon was used to better familiarize all members involved with the process of safely extricating astronauts from the SpaceX spacecraft. This is the first time that multiple SpaceX and NASA teams have fully integrated to work aboard the ship and simulate the recovery process. The teams practiced helping the astronauts exit the capsule and simulated receiving medical attention that may be necessary when in a hypothetical emergency return from the ISS.

NASA astronaut Doug Hurley, along with teams from NASA and SpaceX, rehearse crew extraction from SpaceX’s Crew Dragon. (NASA/Bill Ingalls)

This practice run follows a recent full dress rehearsal of suit-up and pre-flight procedures that were conducted at SpaceX headquarters in Hawthorne, California. Following that dress rehearsal, SpaceflightNow.com reported that a newly installed slide wire emergency egress system was tested at Launch Pad 39A at Kennedy Space Center in Florida where the crewed DM-2 Mission will be launching from.

Crew Dragon’s Demonstration Mission 1 (Demo-1) launch presented SpaceX with a full-fidelity opportunity to hone capsule retrieval practices, but SpaceX teams did not practice astronaut extraction from the capsule – Demo-1 flight was uncrewed aside from an Anthropomorphic Test Device (i.e. dummy) nicknamed Ripley. The rehearsal on Tuesday served as familiarization for teams to extract astronauts from the capsule once it has been recovered aboard GO Searcher while still docked.

On Thursday, August 15th, two days after the above capsule extraction rehearsal, NASA once more posted photos of GO Searcher-related rehearsal operations, this time involving a drill in which astronauts needed to be airlifted immediately to land-based medical facilities. According to local observers and confirmed by the official NASA photos, a helicopter did indeed land on GO Searcher’s dedicated helipad before quickly departing with medically sensitive cargo. Searcher has its own simple medical facilities onboard but they are only capable of dealing with fairly routine concerns, focused primarily on aiding astronauts who are going from half a year in microgravity to full Earth gravity.

While there are still many milestones to get through before Crew Dragon can take flight for the second time, these numerous rehearsals of critical launch and recovery procedures are incredibly important, helping SpaceX and NASA teams hone their working relationship as both prepare to enter a new stage of the Commercial Crew Program. Demo-1 astronaut Col. Bob Behnken summarized it nicely, stating that, “each of these exercises puts us one step closer to fulfilling NASA’s mission of returning astronauts to the International Space Station from U.S. soil.”

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Tesla ‘Mad Max’ gets its first bit of regulatory attention

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Credit: Teslarati

Tesla “Mad Max” mode has gotten its first bit of regulatory attention, as the National Highway Traffic Safety Administration (NHTSA) has asked for additional information on the Speed Profile.

A few weeks ago, Tesla officially launched a new Speed Profile for Full Self-Driving (Supervised) known as “Mad Max,” which overtook the “Hurry” mode for the fastest setting FSD offers.

Tesla launches ‘Mad Max’ Full Self-Driving Speed Profile, its fastest yet

It launched with Full Self-Driving v14.1.2, and it was no secret that the company was looking for a new mode that would cater to more aggressive driving styles.

The release notes showed the description of the Speed Profile as:

“Introduced new speed profile MAD MAX, which comes with higher speeds and more frequent lane changes than Hurry.”

It certainly lived up to its description. In our testing, it was aggressive, fast, and drove similarly to some of the more challenging traffic patterns I’ve come across.

In normal highway driving, it was one of the quicker cars on the road, while other applications saw it be a suitable version for navigating things like rush-hour traffic.

Here’s what my experience with it was:

While Tesla owners have certainly enjoyed the feature and the behaviors of Mad Max, the NHTSA said it is in contact with Tesla about it, looking to gather additional information. Additionally, it said:

“The human behind the wheel is fully responsible for driving the vehicle and complying with all traffic safety laws.”

The important thing to note with Mad Max mode, along with the other Speed Profiles, is that the driver can choose whichever one they’d like, and they all cater to different driving styles.

While Mad Max is more aggressive, modes like “Sloth” and “Standard” are significantly more conservative and can be more suitable for those who are not comfortable with the faster, more spirited versions.

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Tesla shares AI5 chip’s ambitious production roadmap details

Tesla CEO Elon Musk has revealed new details about the company’s next-generation AI5 chip, describing it as “an amazing design.”

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Image used with permission for Teslarati. (Credit: Tom Cross)

Tesla CEO Elon Musk has revealed new details about the company’s next-generation AI5 chip, describing it as “an amazing design” that could outperform its predecessor by a notable margin. Speaking during Tesla’s Q3 2025 earnings call, Musk outlined how the chip will be manufactured in partnership with both Samsung and TSMC, with production based entirely in the United States.

What makes AI5 special

According to Musk, the AI5 represents a complete evolution of Tesla’s in-house AI hardware, building on lessons learned from the AI4 system currently used in its vehicles and data centers. “By some metrics, the AI5 chip will be 40x better than the AI4 chip, not 40%, 40x,” Musk said during the Q3 2025 earnings call. He credited Tesla’s unique vertical integration for the breakthrough, noting that the company designs both the software and hardware stack for its self-driving systems.

To streamline the new chip, Tesla eliminated several traditional components, including the legacy GPU and image signal processor, since the AI5 architecture already incorporates those capabilities. Musk explained that these deletions allow the chip to fit within a half-reticle design, improving efficiency and power management. 

“This is a beautiful chip,” Musk said. “I’ve poured so much life energy into this chip personally, and I’m confident this is going to be a winner.”

Tesla’s dual manufacturing strategy for AI5

Musk confirmed that both Samsung’s Texas facility and TSMC’s Arizona plant will fabricate AI5 chips, with each partner contributing to early production. “It makes sense to have both Samsung and TSMC focus on AI5,” the CEO said, adding that while Samsung has slightly more advanced equipment, both fabs will support Tesla’s U.S.-based production goals.

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Tesla’s explicit objective, according to Musk, is to create an oversupply of AI5 chips. The surplus units could be used in Tesla’s vehicles, humanoid robots, or data centers, which already use a mix of AI4 and NVIDIA hardware for training. “We’re not about to replace NVIDIA,” Musk clarified. “But if we have too many AI5 chips, we can always put them in the data center.”

Musk emphasized that Tesla’s focus on designing for a single customer gives it a massive advantage in simplicity and optimization. “NVIDIA… (has to) satisfy a large range of requirements from many customers. Tesla only has to satisfy one customer, Tesla,” he said. This, Musk stressed, allows Tesla to delete unnecessary complexity and deliver what could be the best performance per watt and per dollar in the industry once AI5 production scales.

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Tesla VP hints at Solar Roof comeback with Giga New York push

The comments hint at possible renewed life for the Solar Roof program, which has seen years of slow growth since its 2016 unveiling.

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Image Credit: Tesla/Twitter

Tesla’s long-awaited and way underrated Solar Roof may finally be getting its moment. During the company’s Q3 2025 earnings call, Vice President of Energy Engineering Michael Snyder revealed that production of a new residential solar panel has started at Tesla’s Buffalo, New York facility, with shipments to customers beginning in the first quarter of 2026. 

The comments hint at possible renewed life for the Solar Roof program, which has seen years of slow growth since its 2016 unveiling.

Tesla Energy’s strong demand

Responding to an investor question about Tesla’s energy backlog, Snyder said demand for Megapack and Powerwall continues to be “really strong” into next year. He also noted positive customer feedback for the company’s new Megablock product, which is expected to start shipping from Houston in 2026.

“We’re seeing remarkable growth in the demand for AI and data center applications as hyperscalers and utilities have seen the versatility of the Megapack product. It increases reliability and relieves grid constraints,” he said.

Snyder also highlighted a “surge in residential solar demand in the US,” attributing the spike to recent policy changes that incentivize home installations. Tesla expects this trend to continue into 2026, helped by the rollout of a new solar lease product that makes adoption more affordable for homeowners.

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Possible Solar Roof revival?

Perhaps the most intriguing part of Snyder’s remarks, however, was Tesla’s move to begin production of its “residential solar panel” in Buffalo, New York. He described the new panels as having “industry-leading aesthetics” and shape performance, language Tesla has used to market its Solar Roof tiles in the past.

“We also began production of our Tesla residential solar panel in our Buffalo factory, and we will be shipping that to customers starting Q1. The panel has industry-leading aesthetics and shape performance and demonstrates our continued commitment to US manufacturing,” Snyder said during the Q3 2025 earnings call.

Snyder did not explicitly name the product, though his reference to aesthetics has fueled speculation that Tesla may finally be preparing a large-scale and serious rollout of its Solar Roof line.

Originally unveiled in 2016, the Solar Roof was intended to transform rooftops into clean energy generators without compromising on design. However, despite early enthusiasm, production and installation volumes have remained limited for years. In 2023, a report from Wood Mackenzie claimed that there were only 3,000 operational Solar Roof installations across the United States at the time, far below forecasts. In response, the official Tesla Energy account on X stated that the report was “incorrect by a large margin.”

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