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SpaceX's in-flight rocket engine failure threatens NASA astronaut launch debut
An in-flight rocket engine failure during SpaceX’s March 18th Starlink launch could pose a threat to the company’s imminent NASA astronaut launch debut according to a statement provided by the space agency yesterday.
SpaceX and NASA are currently working around the clock to prepare a Falcon 9 rocket and Crew Dragon spacecraft for the company’s inaugural astronaut launch, a flight known as Demonstration Mission 2 (Demo-2/DM-2). All launch vehicle and spacecraft hardware – including booster B1058, an expendable upper stage, a spacecraft trunk, and the Crew Dragon capsule itself – are already believed to be at SpaceX’s Florida launch and processing facilities.
Prior to March 18th, the biggest gating items were believed to be a few final parachute tests and a whole lot of paperwork and reviews, as well as some important but less showstopping astronaut training. Unfortunately, SpaceX has suffered two unforeseen issues of varying severity in the last few days, both of which are now all but guaranteed to impact Crew Dragon’s astronaut launch debut schedule.
“According to the CCtCap contracts, SpaceX is required to make available to NASA all data and resulting reports. SpaceX, with NASA’s concurrence, would need to implement any corrective actions found during the investigation related to its commercial crew work prior to its flight test with astronauts to the International Space Station. NASA and SpaceX are holding the current mid-to-late May launch timeframe, and would adjust the date based on review of the data, if appropriate.”
NASA — March 25th, 2020
On March 18th, less than three minutes after liftoff and shortly before stage separation was scheduled, Falcon 9 booster B1048 – on its historic fifth launch attempt – suffered an engine failure visible on SpaceX’s official webcast. By all appearances, Falcon 9’s autonomous flight computer accounted for the engine’s failure, shutdown, and the resultant loss of thrust by burning B1048’s eight remaining engines for several seconds longer than planned.
While that extra few seconds of burn time likely ensured that the rocket’s upper stage was able to make it to the correct orbit after stage separation, roughly five minutes after B1048’s extremely rapid engine failure, contact was lost. For the first time ever, there were no landing burn-related call-outs from SpaceX launch operators, the first sign that something was seriously wrong. A few minutes later, SpaceX’s webcast hosts acknowledged that the booster had been lost, perhaps lacking the propellant it needed to attempt a landing.
For reference, Merlin 1D engines likely consume some ~270 kg (600 lb) of fuel each second. Falcon 9’s landing propellant reserves are believed to be on the order of 50+ metric tons (110,000 lb). Excluding the failed engine, eight Merlin 1Ds burning at full thrust for an additional 5 seconds would consume 20% of the propellant needed for landing; 10 seconds and it would use 40%.
The anomaly was Merlin 1D engine’s first in-flight failure ever. The 2012 failure of one of an original Falcon 9 V1.0’s rocket’s nine Merlin 1C engines is SpaceX’s only other in-flight failure.
It’s likely that B1048’s engine failure was primarily related to the fact that the booster was SpaceX’s pathfinder for a fifth-flight reusability milestone, making it the most reused rocket booster ever launched. NASA currently requires all of its Crew Dragon missions to launch on new Falcon 9 rockets, hopefully mitigating direct corollaries between the Starlink L6 anomaly and astronaut launches. Regardless, the space agency says that the company will now have to complete its internal failure review and implement necessary hardware, software, or rule changes before it’s allowed to launch NASA astronauts.
That investigation could take a matter of weeks, possibly even less, but it’s entirely possible that it could take months – let alone fixing the problems that allowed the in-flight Merlin 1D engine failure to happen in the first place. Ultimately, it will almost certainly make even the first flights of Falcon 9 and Heavy rocket boosters safer, but it could substantially delay SpaceX’s Demo-2 astronaut launch debut. Still targeted no earlier than (NET) mid-to-late May 2020, it’s safe to say that it’s reasonable to expect that schedule to slip over the next 4-6 weeks. Stay tuned for updates.
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Tesla hints at Starlink integration with recent patent
“By employing polymer blends, some examples enable RF transmission from all the modules to satellites and other communication devices both inside and outside the vehicle.”
Tesla hinted at a potential Starlink internet terminal integration within its vehicles in a recent patent, which describes a vehicle roof assembly with integrated radio frequency (RF) transparency.
The patent, which is Pub. No U.S. 2025/0368267 describes a new vehicle roof that is made of RF-transparent polymer materials, allowing and “facilitating clear communication with external devices and satellites.”
Tesla believes that a new vehicle roof design, comprised of different materials than the standard metallic or glass elements used in cars today, would allow the company to integrate modern vehicular technologies, “particularly those requiring radio frequency transmission and reception.
Tesla has recently filed a US patent application on integrating RF transparent materials into the roof structure.
“facilitating clear communication with external devices and satellites”
Tesla fleet is getting @Starlink connectivity integration soon. LFG @Tesla @elonmusk… pic.twitter.com/bLa8YtPLd1
— Chansoo Byeon (@Chansoo) December 9, 2025
Instead of glass or metallic materials, Tesla says vehicles may benefit from high-strength polymer blends, such as Polycarbonate, Acrylonitrile Butadiene Styrene, or Acrylonitrile Styrene Acrylate.
These materials still provide ideal strength metrics for crashworthiness, stiffness for noise, vibration, and harshness control, and are compliant with head impact regulations.
They would also enable better performance with modern technologies, like internet terminals, which need an uninterrupted signal to satellites for maximum reception. Tesla writes in the patent:
“By employing polymer blends, some examples enable RF transmission from all the modules to satellites and other communication devices both inside and outside the vehicle.”
One of the challenges Tesla seems to be aware of with this type of roof design is the fact that it will still have to enable safety and keep that at the forefront of the design. As you can see in the illustration above, Tesla plans to use four layers to increase safety and rigidity, while also combating noise and vibration.
It notes in the patent that disclosed examples still meet the safety requirements outlined in the Federal Motor Vehicle Safety Standards (FMVSS).
Starlink integrated directly into Tesla vehicles would be a considerable advantage for owners. It would come with a handful of distinct advantages.
Initially, the inclusion of Starlink would completely eliminate cellular dead zones, something that is an issue, especially in rural areas. Starlink would provide connectivity in these remote regions and would ensure uninterrupted service during road trips and off-grid adventures.
It could also be a critical addition for Robotaxi, as it is crucial to have solid and reliable connectivity for remote monitoring and fleet management.
Starlink’s growing constellation, thanks to SpaceX’s routine and frequent launch schedule, will provide secure, stable, and reliable internet connectivity for Tesla vehicles.
Although many owners have already mounted Starlink Mini dishes under their glass roofs for a similar experience, it may be integrated directly into Teslas in the coming years, either as an upgrade or a standard feature.
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Tesla supplements Holiday Update by sneaking in new Full Self-Driving version
It seems Tesla was waiting for the Hardware 4 rollout, as it wanted to also deploy a new Full Self-Driving version to those owners, as it appeared in the release notes for the Holiday Update last night.
Tesla has surprised some owners by sneaking in a new Full Self-Driving version with the wide release of the Holiday Update, which started rolling out to Hardware 4 owners on Friday night.
Tesla has issued a controlled and very slow release pattern with the Holiday Update, which rolls out with Software Version 2025.44.25.5.
For the past two weeks, as it has rolled out to Hardware 3 and older Tesla owners, the company has kept its deployment of the new Software Version relatively controlled.
It seems Tesla was waiting for the Hardware 4 rollout, as it wanted to also deploy a new Full Self-Driving version to those owners, as it appeared in the release notes for the Holiday Update last night.
Tesla Full Self-Driving v14.2.1.25 made its first appearance last night to Hardware 4 owners who are members of the Early Access Program (EAP). It appears to be a slight refinement from FSD v14.2.1, which has been out for a couple of weeks.
Tesla v2025.44.25.5 Holiday update incoming
Also Full Self-Driving v14.2.1.25!!! pic.twitter.com/74D7S0UGXz
— TESLARATI (@Teslarati) December 13, 2025
Many owners welcome the new FSD version, us included, because we’ve been less than impressed with v14.2.1. We have experienced some minor regressions with v14.2.1, especially with Speed Limit recognition, Speed Profile tinkering, and parking performance.
As it stands, Full Self-Driving is still particularly impressive, but Tesla is evidently having an issue with some of the adjustments, as it is still refining some of the performance aspects of the suite. This is expected and normal with some updates, as not all of them are an improvement in all areas; we routinely see some things backtrack every once in a while.
This new FSD version is likely to take care of those things, but it also includes all of the awesome Holiday Update features, which include:
- Grok with Navigation Commands (Beta) – Grok will now add and edit destinations.
- Tesla Photobooth – Take pictures inside your car using the cabin-facing camera
- Dog Mode Live Activity – Check on your four-legged friend on your phone through periodic snapshots taken of the cabin
- Dashcam Viewer Update – Includes new metrics, like steering wheel angle, speed, and more
- Santa Mode – New graphics, trees, and a lock chime
- Light Show Update – Addition of Jingle Rush light show
- Custom Wraps and License Plates – Colorizer now allows you to customize your vehicle even further, with custom patterns, license plates, and tint
- Navigation Improvements – Easier layout and setup
- Supercharger Site Map – Starting at 18 pilot locations, a 3D view of the Supercharger you’re visiting will be available
- Automatic Carpool Lane Routing – Navigation will utilize carpool lanes if enabled
- Phone Left Behind Chime – Your car will now tell you if you left a phone inside
- Charge Limit Per Location – Set a charge limit for each location
- ISS Docking Simulator – New game
- Additional Improvements – Turn off wireless charging pad, Spotify improvements, Rainbow Rave Cave, Lock Sound TRON addition
Tesla also added two other things that were undocumented, like Charging Passport and information on USB drive storage to help with Dashcam.
Tesla is updating Cybertruck owners on its timeline of a massive feature that has yet to ship: Powershare with Powerwall.
Powershare is a bidirectional charging feature exclusive to Cybertruck, which allows the vehicle’s battery to act as a portable power source for homes, appliances, tools, other EVs, and more. It was announced in late 2023 as part of Tesla’s push into vehicle-to-everything energy sharing, and acting as a giant portable charger is the main advantage, as it can provide backup power during outages.
Cybertruck’s Powershare system supports both vehicle-to-load (V2L) and vehicle-to-home (V2H), making it flexible and well-rounded for a variety of applications.
However, even though the feature was promised with Cybertruck, it has yet to be shipped to vehicles. Tesla communicated with owners through email recently regarding Powershare with Powerwall, which essentially has the pickup act as an extended battery.
Powerwall discharge would be prioritized before tapping into the truck’s larger pack.
However, Tesla is still working on getting the feature out to owners, an email said:
“We’re writing to let you know that the Powershare with Powerwall feature is still in development and is now scheduled for release in mid-2026.
This new release date gives us additional time to design and test this feature, ensuring its ability to communicate and optimize energy sharing between your vehicle and many configurations and generations of Powerwall. We are also using this time to develop additional Powershare features that will help us continue to accelerate the world’s transition to sustainable energy.”
Owners have expressed some real disappointment in Tesla’s continuous delays in releasing the feature, as it was expected to be released by late 2024, but now has been pushed back several times to mid-2026, according to the email.
Foundation Series Cybertruck buyers paid extra, expecting the feature to be rolled out with their vehicle upon pickup.
Cybertruck’s Lead Engineer, Wes Morrill, even commented on the holdup:
As a Cybertruck owner who also has Powerwall, I empathize with the disappointed comments.
To their credit, the team has delivered powershare functionality to Cybertruck customers who otherwise have no backup with development of the powershare gateway. As well as those with solar…
— Wes (@wmorrill3) December 12, 2025
He said that “it turned out to be much harder than anticipated to make powershare work seamlessly with existing Powerwalls through existing wall connectors. Two grid-forming devices need to negotiate who will form and who will follow, depending on the state of charge of each, and they need to do this without a network and through multiple generations of hardware, and test and validate this process through rigorous certifications to ensure grid safety.”
It’s nice to see the transparency, but it is justified for some Cybertruck owners to feel like they’ve been bait-and-switched.
Tesla hints at Starlink integration with recent patent
Tesla supplements Holiday Update by sneaking in new Full Self-Driving version
