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SpaceX rapidly tests, ships Falcon 9 second stage for next NASA astronaut launch

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4 years ago

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SpaceX has shipped, tested, and delivered the new Falcon 9 upper stage tasked with carrying the company’s next Crew Dragon astronauts to orbit as early as October 30th.

Offering rare insight into the kind of timelines and margins SpaceX operates on for even its most important missions, a Falcon upper stage bearing NASA’s ‘worm’ logo and ‘meatball’ insignia was spotted by a local resident and photographer on October 2nd. Thus far, the only SpaceX rockets that have flown with NASA iconography are those supporting Crew Dragon launches, making them a dead giveaway for Crew Dragon launch hardware.

After Demo-2, SpaceX’s May 2020 astronaut launch debut, the company moved those decals from Falcon 9’s booster – liable to fly any number of non-NASA missions later in life – to each NASA crew mission’s expendable Falcon second stage (S2). Since then, Crew-1 (November 2020) and Crew-2 (April 2021) have both launched with NASA logos on their second stages and Crew-3 now looks set to continue that tradition.

A new Falcon upper stage bearing NASA insignias was first spotted in Texas on October 2nd.
Less than two weeks later, that same upper stage may have arrived in Cape Canaveral, Florida.

Thanks to the watchful eye of local resident turned SpaceX fan Reagan Beck, it was actually possible to identify Crew-3’s Falcon 9 upper stage as soon as it was spotted at the company’s McGregor, TX development and testing facilities on October 2nd. While there was technically a tiny chance that it could be for one of several upcoming NASA spacecraft launches or even for Crew Dragon’s April 2022 Crew-4 mission, the likeliest destination by far for the NASA-branded Falcon S2 was Crew-3.

Due partially to the fact that Falcon booster qualification testing typically takes McGregor at least two or so weeks but mainly to the seemingly razor-thin schedule margins it would imply, there was some understandable skepticism that the upper stage was bound to launch Crew-3 just four weeks after it was first spotted. Moreso, Crew Dragon typically rolls out to the launch pad on Falcon 9 at least 5-7 days before launch to allow extra time for an integrated static fire, final checkouts, and a ‘dry dress’ practice runs for each mission’s crew.

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Further, even after completing static fire qualification testing in McGregor, Crew-3’s Falcon stage would still need to be packaged up, transported more than a thousand miles by road, carefully unpackaged at a SpaceX launch site or hangar, outfitted with a Merlin Vacuum nozzle extension, installed on the mission’s Falcon 9 booster, and mated to Crew Dragon itself before that pad rollout can occur. In other words, rather than Crew-3’s exact October 30th launch date, the mission’s upper stage would likely need to arrive at SpaceX’s Kennedy Space Center (KSC) Pad 39A launch facilities at least 9-10 days before launch.

Realistically, that means that from the moment the NASA-branded upper stage first spotted on a McGregor test stand, it had maybe two weeks to complete qualification testing and ship out to Pad 39A. With practically no context, that seemed like a stretch at the time – particularly for a single-engine Falcon second stage explicitly tasked with safely delivering four astronauts to orbit. In reality, McGregor’s Falcon S2 testing is apparently far faster than booster testing and the presumed Crew-3 stage seemingly passed qualification testing and vacated the test stand less than five days after it was installed.

In theory, that left the McGregor team about a week to complete post-test inspections, clean the interior of its propellant tanks, and prepare the stage for the last leg of its journey to Florida. SpaceX seemingly managed that without issue and a new Falcon upper stage potentially meant for Crew-3 was spotted in Florida just a few miles away from a SpaceX launch site on October 14th.

However, per additional photos and reports from Reagan, McGregor’s second stage test team has been incredibly busy over the last month or so. Prior to the Crew-3 stage’s arrival, another second stage completed qualification testing between September 21st and 28th. Crew-3’s S2 was installed on October 2nd and removed by the 7th. Wasting no time, another second stage was installed on the same stand on October 10th and apparently completed testing by the 13th – equivalent to a new upper stage qualified every week. Even if the Falcon stage that arrived at Cape Canaveral on October 14th isn’t Crew-3’s, then, Crew-3’s can’t be far behind.

The first orbit-ready Crew Dragon spacecraft stands beside its human-rated Falcon 9 rocket (upper stage included) in December 2018. (SpaceX)

Ultimately, SpaceX appears to be testing and shipping one of two integral Falcon 9 stages for a crucial, schedule-sensitive NASA astronaut launch with schedule margins measured in hours or single-digit days. That’s a far cry from competitors Arianespace and ULA and even NASA itself, which generally deliver flight hardware months in advance. Eleven years since Falcon 9’s launch debut, every Falcon second stage that has made it through stage separation – 127 of 127 – has successfully ignited its Merlin Vacuum engine one or several times and delivered its payload(s) to the correct orbit(s). Well over half of those successful launches were completed in the last three and a half years – and with the same Falcon 9 upper stage variant now routinely tasked with carrying astronauts to orbit.

In other words, delivering a NASA Crew mission’s Falcon second stage less than two weeks before the assembled rocket is scheduled to roll out to the launch pad may seem a tad reckless, it’s more likely that it’s evidence of SpaceX’s second stage build/test teams and facilities operating as an incredibly reliable, well-oiled machine.

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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 Robotaxi’s biggest challenge seems to be this one thing

That big bright thing in the sky might be Tesla’s biggest challenge in terms of Robotaxi.

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5 hours ago

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June 25, 2025

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Credit: Tesla

Tesla Robotaxi launched just a few days ago to a limited number of riders in Austin, Texas, but its biggest challenge seems to be how the automaker will figure out one thing: the Sun.

Among the company’s unique strategies, its emphasis on using cameras for self-driving is perhaps the most interesting. No other company has adopted the same strategy, as others have relied on cameras with either sensors or LiDAR rigs to accomplish their self-driving deployments.

Tesla, on the other hand, has called LiDAR unnecessary. CEO Elon Musk once called it “a fool’s errand,” stating it was not needed to build an effective self-driving fleet of vehicles.

Musk compared cameras to eyes. Humans don’t need sensors or LiDAR to operate vehicles on the road, so why should cars? This brought up some questions, especially regarding sun glare. Musk said that Tesla would use direct photon counting to see directly into brigt sunlight or even in the darkest conditions at night.

His quote during a recent earnings call was:

“Actually, it does not blind the camera. We use an approach which is direct photon count. When you see a processed image, so the image that goes from the sort of photon counter — the silicon photon counter — that then goes through a digital signal processor or image signal processor, that’s normally what happens. And then the image that you see looks all washed out, because if you point the camera at the sun, the post-processing of the photon counting washes things out.”
So far, this strategy has yielded mixed results. We have seen examples of both:

The Good

We’ve had a handful of people state that they have had no issue using the Robotaxi when it is driving into direct sunlight.

There are plenty of examples:

The Bad

The Verdict

This is obviously a weird case, and it seems that this could be one of the challenges Tesla will face with the deployment of Robotaxi.

While it will get figured out, this is something that could ultimately push back Tesla’s goal of having no safety monitor in the vehicles. However, the instance will be learned and used to improve in the future through its Neural Nets.

The first intervention was captured yesterday, requiring the Tesla safety monitor to stop the vehicle manually on the car’s touchscreen.

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Tesla owners take stand as Stockholm insists on blocking FSD tests

Despite the Tesla owners’ efforts, city officials appear unwilling to budge.

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5 hours ago

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June 25, 2025

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Credit: Tesla China

Tesla owners in Sweden are taking it upon themselves to lobby for the approval of FSD-style tests in the City of Stockholm. The owners’ efforts come amidst city officials’ continued refusal to allow Tesla to test its autonomous driving system in the capital.

In open letters and social media posts, Tesla owners have urged Stockholm to reconsider its stance, pointing to broader support for FSD trials across Europe. But despite their efforts, city officials appear unwilling to budge, reinforcing the capital’s hardline stance on the Elon Musk-led EV maker.

Public support shows brand loyalty

A group of Swedish Tesla owners recently sent an open letter to Stockholm leaders. Among them is Alexander Kristensen, who has written a letter to officials urging them to allow Tesla to test FSD in the region.

“Members of the Traffic Committee are politically appointed by the Stockholm City Council, whose mandate is determined by the popular vote. Your stance—continuing to block a conditional pilot of FSD— is thus a political decision and fully subject to the electorate’s judgment in the next municipal election.

“When the City prevents tests that could validate and refine the technology locally, it is perceived as hampering life-saving innovation,” the Tesla owners wrote.

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The Swedish Transport Administration issued a response, acknowledging the Tesla owners’ feedback. The Transport Administration noted that it could proceed to grant a permit for Tesla to test FSD, but the company would still have to secure approval from local governments where the FSD-style tests will be conducted.

Stockholm remains firm

Despite this, Stockholm doubled down shortly after, stating that Tesla’s FSD software remains prohibited on city roads.

“Thank you for your comments and for taking an interest in traffic issues concerning the City of Stockholm. As previously stated, the City’s assessment of the current application remains unchanged and our position is set out in the opinion,” the City of Stockhom wrote.

In light of the city’s response, some Tesla owners have vowed to campaign against current officials in the next election.

The push for FSD testing comes as Tesla faces ongoing challenges in Sweden, including a labor dispute with unions over collective bargaining agreements. Since late 2023, the conflict has resulted in strikes, blockades, and legal battles, none of which appear close to resolution. Despite regulatory and labor headwinds, Tesla continues to expand in the region, including the recent installation of Superchargers in union-backed areas.

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xAI welcomes Memphis pollution results, environmental groups push back

Tests were conducted at Macedonia Church in Boxtown, The Links at Whitehaven, and City Hall Downtown.

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12 hours ago

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June 25, 2025

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xAI-supercomputer-memphis-environment-pushback
(Credit: xAI)

The City of Memphis has released initial air quality test results from three sites across the city, including one near Elon Musk’s xAI data center in South Memphis. 

According to city officials, the results showed no dangerous levels of pollutants. “At every site and for every pollutant tested, levels were either too low to detect or well below established safety thresholds,” the city’s report read.

xAI Welcomes Air Quality Test Results

Tests were conducted at Macedonia Church in Boxtown, The Links at Whitehaven, and City Hall Downtown. Memphis Mayor Paul Young stated that the data only represents a “snapshot in time” and that continued monitoring will take place.

“The City doesn’t control air quality regulations, but we stepped up to find answers. The initial results showed no dangerous levels of air pollutants at any of the tested sites. We are committed to ongoing testing to continue to inform and protect our community,” Mayor Young stated.

xAI, which opened a facility in Boxtown to house its Colossus supercomputer, welcomed the city’s initial findings. The artificial intelligence startup shared its comments in a post on social media platform X.

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“xAI welcomes the independent third-party data showing no dangerous pollutant levels at test sites near our Memphis data center. We have built a world-class data center in Memphis and we couldn’t have done it without the support of the local community and its leaders,” the company stated.

Critics Are Not Satisfied

Environmental advocates and local leaders, however, were not satisfied with the city’s initial tests. The Southern Environmental Law Center criticized the city’s approach, arguing that smog-forming emissions, including nitrogen oxides from xAI’s turbines, pose health risks that the city’s testing did not account for, as noted in a FOX 13 Memphis report.

“The city failed to measure ozone pollution–better known as smog–which we already know is a major problem in the Memphis area… As community members have warned for the last year, smog-forming pollution is a major concern with the unpermitted turbines being run at xAI’s South Memphis data center,” the group noted.

State Representative Justin J. Pearson (D-Memphis) echoed the group’s criticism.

“We do not need any more misleading reports that are more concerned with finding a conclusion conducive to Mayor Young’s unwavering support of xAI, rather than discovering the truth. Our review of the information released by the City of Memphis earlier this evening revealed a glaring and critical omission in their pollution testing and results: the monitoring of ozone which is a considerable factor in air pollution problems in Memphis,” he noted.

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