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SpaceX wins NASA approval to launch astronauts on reused rockets and spacecraft

SpaceX appears to have been granted permission to launch NASA astronauts on flight-proven spacecraft and rockets as early as 2021. (SpaceX)

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SpaceX appears to have won NASA’s approval to launch astronauts on reused Falcon 9 rockets and Crew Dragon spacecraft a matter of days after the company’s astronaut launch debut went off without a hitch.

Ever since SpaceX began landing and reusing orbital-class Falcon 9 boosters some 15 months after it won a NASA contract to develop Crew Dragon, the obvious possibility that the two groundbreaking technologies might one day meet has always floated just under the surface. Almost without fail, most joint NASA/SpaceX press conferences will receive a question or two about whether either party is thinking about or working towards astronaut launches on flight-proven spacecraft. Encouraged by the fact that partner Boeing’s separate Starliner spacecraft was sold to NASA with reusability in mind from the start, those questions continued up until (and after) the day SpaceX became the first private company in history to launch astronauts into orbit.

In a wholly unexpected turn of events, a modification to SpaceX’s ~$3.1 billion NASA Commercial Crew Program (CCP) contract was spotted on June 3rd. Without leaving much room for interpretation, the contract tweak states that SpaceX is now “[allowed to reuse] the Falcon 9 launch vehicle and Crew Dragon spacecraft beginning with” its second operational astronaut launch, known as Post Certification Mission-2 (PCM-2) or Crew-2. Given the spectacular, hiccup-free success of SpaceX’s inaugural astronaut launch and International Space Station (ISS) arrival just 3-4 days prior, it’s safe to say that NASA is extremely happy with the results of the mission.

SpaceX could soon reuse the vast majority of rocket and spacecraft hardware involved in its astronaut launches, potentially dramatically cutting the cost of sending humans into orbit. (Richard Angle)

Without a shred of doubt, SpaceX has worked tirelessly for years to earn enough of NASA’s technical trust to permit crewed launches on flight-proven hardware, a possibility that even the optimists in the crowd assumed was distant at best. It has almost always been an uphill battle for SpaceX – a fact made especially clear when framed beside partner Boeing. An inherently conservative organization, NASA has repeatedly given Boeing and its more traditional Starliner spacecraft and development approach the benefit of the doubt while frequently tearing into the nooks and crannies of SpaceX and Crew Dragon over half a decade of cooperation.

While functioning more like an anchor when SpaceX finds itself working with conservative, stubborn organizations like NASA and US military branches, the company’s wholly non-traditional style of development has secured technical success after technical success. Over the course of the second half of SpaceX’s 20-mission NASA Commercial Resupply Services 1 (CRS1) contract, the company has still managed to successfully launch dozens of tons of cargo to the space station with flight-proven spacecraft and boosters. From CRS-11 to CRS-20, five missions featured reused Falcon 9 boosters and all but one of those 10 flights featured once or even twice-flown Cargo Dragon spacecraft.

Cargo Dragon C113 bares its scorched heat shield after completing CRS-17 – its third orbital mission – and returning to port on June 4th, 2019. (Pauline Acalin)
On CRS-18, a flight-proven Dragon and Falcon 9 booster teamed up for a uniquely economical space station resupply mission. (SpaceX)

In short, SpaceX has demonstrated more than a dozen times to NASA that it’s fully capable of building, launching, and reusing orbital-class rockets and spacecraft. Additionally, before an unrelated design flaw destroyed the spacecraft during post-recovery testing, SpaceX successfully launched, recovered, and refurbished Crew Dragon capsule C201 in March 2019, demonstrating its dramatically improved reusability. While suborbital, Crew Dragon C205’s January 2020 In-Flight Abort (IFA) test also likely helped demonstrate the new spacecraft’s reusability and gave NASA more experience with the reuse of Falcon 9 Block 5 rockets as B1046’s fourth launch.

Every step along the way, SpaceX has put its money where its mouth is and proven that it’s more than capable of doing what much larger, more traditional companies have only claimed to be capable of – and often months or even years before its competitors and for hundreds of millions to billions of dollars less. While it’s much more likely that NASA has yet to actually certify SpaceX’s Crew Dragon spacecraft and Falcon 9 boosters for flight-proven astronaut launches, the June 3rd contract modification – at a minimum – signifies the space agency’s expeditious intent to do so. What is unambiguous is the schedule it lays out: SpaceX could potentially launch astronauts on a flight-proven rocket and spacecraft as early as its second operational taxi mission to the ISS.

Scheduled to launch for the first time as early as August 30th, 2020, the above Crew Dragon capsule and Falcon 9 booster could become the first to launch astronauts into orbit twice. (SpaceX)

Known as PCM-2 or Crew-2, the mission is scheduled to follow Crew Dragon’s first operational astronaut launch – Crew-1 – by roughly six months. Contingent upon Crew Dragon Demo-2’s safe return of NASA astronauts Bob Behnken and Doug Hurley later this year, Crew-1 is tentatively scheduled to launch on August 30th, although it could potentially launch even sooner. If successful, Crew-2 should follow as soon as mid-2021 and could potentially reuse Crew-1’s Falcon 9 booster and the Demo-2 or Crew-1 Dragon capsule.

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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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Tesla Cybercab Event: what to expect from Austin

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Credit: Tesla

Tesla is set to launch Cybercab on Thursday at an event in Austin, Texas, which will officially bring the company’s first steering wheel-less and pedal-less vehicle to a limited number of consumers for the first time.

The event, which is invite-only, is still thin on details: we’ll be there, and it seems the event will be held at Gigafactory Texas, but the launch of this vehicle truly relies on it being operational outside of the factory and on public roads.

Nevertheless, there are some big things to expect, and other things to temper expectations on. For what it’s worth, we believe this event could be perhaps the biggest indication that Tesla is ready to truly enter a new phase and chapter in its historic story.

Tesla Cybercab’s First Foray into the Public with Real-World Riders

Cybercab will likely hit the streets of Austin and the surrounding areas, likely in the established geofence that Tesla has expanded on for the past 14 months. Just yesterday, Tesla expanded it once again by 9 percent.

Tesla will put, for the first time, a vehicle without any manual controls on public roads, likely without any help from teleoperators. This is a truly groundbreaking development if it comes through in this fashion: it would be groundbreaking for Tesla to roll out a truly driverless ride-hailing vehicle.

Cybercab Has Already Been Unveiled

This is not an unveiling event. Cybercab has been released for nearly two years, as Tesla first showed it to the public on October 10, 2024.

FIRST LOOK: Tesla ‘Cybercab’ Robotaxi makes its global debut

While there is some small speculation that Tesla could release the Roadster at the event as a surprise, it seems more likely the focus will be on the Cybercab and the huge accomplishment that will come with releasing a vehicle with no manual controls.

There Will Be a Lot of Hype

What’s important to remember about the Cybercab event is that Tesla will continue to prioritize safety and the rollout will likely be slow, just as it has been with Robotaxi.

One of the biggest complaints about Robotaxi is vehicle population, and the fact that the wait for a ride, at least in some instances, has been longer than most want to admit.

Tesla Cybercab fleet grows in Austin ahead of launch event

It will take time for this project to truly scale. It will take time for Tesla to roll this out in a large fashion. The important thing to note is that they are doing it, and they’re doing it with a vehicle that is completely engineered and built internally. That’s something no other ride-hailing service can say.

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SpaceX would not exist if this crucial early launch failed, Musk says

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Credit: SpaceX

Elon Musk recently restated a fact that still defines SpaceX’s origin story: if Falcon 1’s fourth launch had failed, the company would not exist. The comment answered a reminder that after three consecutive losses, SpaceX had money for only one more attempt.

On X, Peter Diamandis said that the present-day acknowledgement of SpaceX’s success does not discount the rough start the company had. “Almost nobody remembers that Elon’s first rocket failed three times, and there was money for exactly only one more attempt.”

Musk said, “If the 4th launch had failed, SpaceX would not exist.”

In late 2008, the firm was nearly out of cash. Another failure would have ended payroll, closed the Hawthorne factory, and left the Falcon 9 and Dragon programs as unfinished drawings.

The first flight lifted off from Omelek Island on 24 March 2006. Thirty-three seconds later, a corroded aluminum fitting on a fuel line leaked. Kerosene ignited around the Merlin engine, control was lost, and the vehicle came apart. The small DARPA payload, FalconSAT-2, survived the short flight only to land on a storage shed near the pad. Investigators later traced the fitting to a materials mix-up that should never have reached the rocket.

Flight 2, on 21 March 2007, looked far better at first. The first stage burned cleanly and handed off to the Kestrel-powered upper stage. The vehicle crossed 100 kilometers and reached a peak of about 289 kilometers. Then propellant slosh in the second-stage tank started a circular coning motion that grew until the engine shut down. Telemetry faded as the stage tumbled, and SpaceX had reached space but not orbit. Over the next year, the team redesigned everything from the ground up, including tanks, baffles, and the new regeneratively cooled Merlin 1C.

That engine flew on Flight 3 on 2 August 2008. The first stage performed almost perfectly and reached 217 kilometers. After main-engine cutoff, leftover fuel in the cooling channels produced a faint residual thrust, roughly 10 pounds per square inch of chamber pressure. On a Texas test stand, the effect was invisible beneath ambient air pressure. In vacuum it was enough to push the spent first stage back into the second stage after separation. The stages collided, the upper stage spun, and the mission was lost. Musk later said a slightly longer delay before staging would have saved the flight.

Six weeks later, the team assembled Flight 4 from remaining parts and flew it on 28 September 2008 at 23:15 UTC. The payload was Ratsat, a 165-kilogram aluminum mass simulator built in-house. Staging was delayed so residual thrust could decay. The Kestrel ignited, the fairing split away, and nine and a half minutes after liftoff the vehicle was in orbit. After a coast, the second stage restarted, settling into a 621-by-643-kilometer path at 9.35 degrees inclination. Falcon 1 became the first privately developed liquid-fueled rocket to reach Earth orbit. Musk called the insertion “middle of the bull’s-eye.”

SpaceX restores a Falcon 1 rocket for 10th anniversary of first launch success

That success unlocked NASA’s Commercial Resupply Services award later that year. Without it, there would have been no Falcon 9, no reusable first stages, and no Dragon cargo or crew flights to the International Space Station. Launch prices would have remained far higher. Starlink’s constellation would not exist; broadband from low Earth orbit would still be a paper concept.

Ride-share markets, high launch cadence, and the current pace of lunar and Mars hardware would be years behind. Communications, Earth observation, and the cost of putting anything into space would look more like the 2000s than the 2020s.

One extra second of residual thrust in August 2008 would have written a different decade.

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Tesla surges Robotaxi fleet ahead of Cybercab launch event

Tesla’s unsupervised robotaxi fleet quietly grew sevenfold in three weeks just before Cybercab Day arrives.

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Tesla’s unsupervised Robotaxi fleet has grown far faster than the public numbers suggested, and the timing lines up with the company’s biggest autonomy showcase yet. According to data compiled by the crowdsourced Robotaxi Tracker, Tesla now has nearly 200 vehicles operating without a safety monitor across Austin, Dallas and Houston, yielding a roughly 7X increase in about three weeks.

The jump lands four days before this week’s Tesla Cybercab launch event in Austin, where the company plans to show off its purpose-built, two-seat robotaxi with no steering wheel or pedals in a live commercial setting for the first time. Stick with us on X and Facebook for live reporting from the event.

The strategic logic is straightforward. Tesla has spent the past year scaling Robotaxi in small, deliberate steps, first widening geofences, then extending operating hours, then quietly growing fleet size, usually with little advance notice. Ashok Elluswamy told investors on the Q2 earnings call that the program had logged more than 380,000 unsupervised miles with zero notable incidents, a safety record the company has leaned on to justify moving slowly. Critics have used the flip side of that caution, a fleet that appeared stuck around two dozen vehicles for months, as evidence that Tesla’s driverless ambitions were outrunning its actual deployment.

A fleet quietly scaling to nearly 200 vehicles right before Cybercab Day undercuts that argument without Tesla having to say anything about it directly. It also sets up the event to do double duty. Rather than simply introducing new hardware, Tesla can point to an operating base of unsupervised Model Ys already running at meaningful scale, then argue the Cybercab, which uses the same underlying Full Self-Driving stack according to earlier coverage of the fleet’s software upgrades, is a natural next steps. Tesla has separately been registering the two-seat Cybercabs with Texas regulators this week, with the count climbing from seven to 45 in a matter of days.

The two ramps, one in software-driven Model Y deployment and one in physical Cybercab registrations, are happening in parallel rather than in sequence. That suggests Tesla wants Thursday’s event to land as proof that the robotaxi business is already running at scale, not just a reveal of a new vehicle shape. Whether the unsupervised numbers hold up once Cybercabs start mixing into the same fleet is the detail worth watching once the event wraps.

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