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Crew Dragon is lifted off the deck of SpaceX recovery vessel GO Searcher after safely arriving at Port Canaveral, March 10th. (NASA) Crew Dragon is lifted off the deck of SpaceX recovery vessel GO Searcher after safely arriving at Port Canaveral, March 10th. (NASA)

SpaceX

SpaceX CEO Elon Musk says Crew Dragon reusability a “major improvement”

Crew Dragon is lifted off the deck of SpaceX recovery vessel GO Searcher after safely arriving at Port Canaveral, March 10th. (NASA)

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SpaceX CEO Elon Musk says that the company’s next-generation Crew Dragon spacecraft is a “major improvement” over its Cargo Dragon (Dragon 1) predecessors after successfully demonstrating a number of reusability-focused upgrades during the vehicle’s launch and splashdown debut.

Even as SpaceX’s longer-term development groups aim to make the company’s Dragon spacecraft all but redundant with Starship and Super Heavy, the apparent success of Crew Dragon’s upgrades will be valuable for years to come. Ultimately, “major” improvements in reusability will allow SpaceX to reuse Dragon 2 far more efficiently, improving availability for both its Crew and Cargo programs and potentially cutting the operating cost and longevity of each spacecraft as the company begins to transition its workforce to BFR.

Although the question cuing Musk was non-specific, the SpaceX CEO immediately focused his reply on whether or not unspecified “upgrades” to Crew Dragon were able to keep sensitive hardware dry. SpaceX’s Cargo Dragon program has roughly seven years of experience with launching, recovering, and refurbishing orbital-class spacecraft after ocean landings and the subsequent seawater immersion. The fact that the Dragon 2 concept was almost immediately demonstrated with propulsive land-landing capabilities speaks to just how annoying a problem it was to try to keep an orbital spacecraft easily reusable while still relying upon water landing for recovery.

As it turns out, many of the engineering solutions best known to ensure structural and thermal integrity of a spacecraft on-orbit are often at ends with the separate task of ensuring that the same spacecraft remains thoroughly water-proof through launch, reentry, and splashdown. Many of these problems center around the materials that are best for each solution. The sorts of polymers (i.e. plastics) best known for their roles in sealing certain things off from other things are frequently very pliable, soft, and flexible. The orbital environment is extremely unfriendly to polymers like this, where constant and extreme thermal cycling couples with vacuum, radiation, and something known as atomic (or free radical) oxygen to rapidly turn pliable polymers brittle.

Different sealants and plastic or rubber gaskets are visible all over Crew Dragon, ranging from the red gasket around the nose cone area to white lines filling in gaps between the spacecraft’s dozens of different external panels.

A ‘brittle seal’, as many will know, is an oxymoron. Sealants that become brittle in space often scarcely behave like sealants at all after weeks (or months) in orbit, meaning that their ability to prevent moisture intrusion can be dramatically deteriorated. From an engineering perspective, Crew Dragon’s many seals and gaskets are first and foremost intended to protect the spacecraft from the elements while still on Earth, where static fire attempts and weather during launch windows could require it to weather extreme heat, cold, rainstorms, ice, and high winds. SpaceX engineers appear to have managed to solve the latter problem while also accounting for a need to protect the spacecraft after launch for the sake of easier refurbishment.

However, sealing the spacecraft from the elements – both before and after launch – is just one of many challenges for safe operations and efficient reusability. Up next, as Musk notes, is protecting Crew Dragon’s 16 Draco maneuvering thrusters and 8 SuperDraco abort thrusters from water damage, as well as sealing off vulnerable avionics for reuse. With respect to avionics, Musk is very likely referring to the electronics and sensing equipment housed under Dragon 2’s retractable nose cone, a new feature for SpaceX.

SpaceX's 'DragonFly' prototype was briefly used to test Dragon 2's propulsive landing capabilities before the program was cancelled. Most of the technology remains a part of Crew Dragon, however... (SpaceX)
Crew Dragon featured intriguing panels covering its Super Draco engine nozzles, presumably meant to prevent water from entering. (NASA)

Due to the fact that Crew Dragon’s SuperDraco abort thrusters are only meant to be used in a namesake abort scenario, SpaceX appears to have chosen to implement a more permanent solution for protecting them from water intrusion after splashdown. The challenge of panels like those covering the SuperDracos is that they need to be easily destructible to prevent a cascade of high-velocity debris from wreaking havoc in the event of ignition. They also need to survive the conditions on orbit, make it through the heat and buffeting of reentry and descent, and survive the initial impact with the ocean surface, all while keeping SuperDracos dry.

As such, it should come as no surprise to find CEO Elon Musk praising the engineering behind the presumably successful solutions to these complex problems, although credit is also due to the technicians that turned CAD files, test results, and aspirations into practical, functioning hardware.

An overview of the expected modifications needed to turn a Crew Dragon into a Cargo Dragon 2. (NASA OIG)

If Crew Dragon can achieve a similar level of success after spending more like half a year in space during operational crew transport missions, the spacecraft’s reusability improvements will end up benefiting both Crew Dragon and Cargo Dragon 2. The Cargo variant of Dragon 2 is designed as a relatively minor modification to flight-proven Crew Dragon capsules and slightly-upgraded trunks and could debut as early as mid-2020 after Cargo Dragon 1 enters retirement.

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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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Starship Flight 10 rescheduled as SpaceX targets Monday launch

SpaceX said it is now targeting Monday evening for Starship’s 10th flight test.

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Credit: SpaceX/X

SpaceX stood down from its planned Starship Flight 10 on Sunday evening, citing an issue with ground systems. 

The launch attempt was scheduled during a one-hour window that opened at 7:30 p.m. ET, but it was called off just 17 minutes before the window opened. SpaceX said it is now targeting Monday evening for Starship’s 10th flight test.

Flight 10 rescheduled

A lot of excitement was palpable during the lead up to Starship Flight 10’s first launch window. After the failures of Starship Flight 9, many were interested to see if SpaceX would be able to nail its mission objectives this time around. Starship itself seemed ready to fly, with the upper stage being loaded with propellant as scheduled. Later on, SpaceX also noted that Starship’s Super Heavy booster was also being loaded with propellant.

However, 17 before the launch window opened, SpaceX noted that it was “standing down from today’s tenth flight of Starship to allow time to troubleshoot an issue with ground systems.” Elon Musk, in a post on X, further clarified that a “ground side liquid oxygen leak needs to be fixed.” Musk did state that SpaceX will attempt Flight 10 again on Monday, August 25, 2025.

Starship and SpaceX’s development goals

The fully integrated Starship system is the tallest and most powerful rocket ever built, standing over 400 feet when stacked. Composed of the reusable Super Heavy booster and the Starship upper stage, the vehicle is central to SpaceX’s long-term ambitions of lunar and Martian missions. NASA has already selected Starship as the crewed lunar lander for Artemis, with its first astronaut landing mission tentatively set for 2027, as noted in a Space.com report.

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So far, Starship has flown nine times from Starbase in Texas, with three launches this year alone. Each flight has offered critical data, though all three 2025 missions encountered notable failures. Flight 7 and Flight 8 ended in explosions less than 10 minutes after launch, while Flight 9 broke apart during reentry. Despite setbacks, SpaceX has continued refining Starship’s hardware and operations with each attempt. Needless to say, a successful Flight 10 would be a significant win for the Starship program.

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SpaceX Starship Flight 10: What to expect

SpaceX implemented hardware and operational changes aimed at improving Starship’s reliability.

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Credit: SpaceX

SpaceX is preparing to launch the tenth test flight of its Starship vehicle as early as Sunday, August 24, with the launch window opening at 6:30 p.m. CT. 

The mission follows investigations into anomalies from earlier flights, including the loss of Starship on its ninth test and a Ship 36 static fire issue. SpaceX has since implemented hardware and operational changes aimed at improving Starship’s reliability.

Booster landing burns and flight experiments

The upcoming Starship Flight 10 will expand Super Heavy’s flight envelope with multiple landing burn trials. Following stage separation, the booster will attempt a controlled flip and boostback burn before heading to an offshore splashdown in the Gulf of America. One of the three center engines typically used for landing will be intentionally disabled, allowing engineers to evaluate whether a backup engine can complete the maneuver, according to a post from SpaceX.

The booster will also transition to a two-engine configuration for the final phase, hovering briefly above the water before shutdown and drop. These experiments are designed to simulate off-nominal scenarios and generate real-world data on performance under varying conditions, while maximizing propellant use during ascent to enable heavier payloads.

Starship upper stage reentry tests

The Starship upper stage will attempt multiple in-space objectives, including deployment of eight Starlink simulators and a planned Raptor engine relight. SpaceX will also continue testing reentry systems with several modifications. A section of thermal protection tiles has been removed to expose vulnerable areas, while new metallic tile designs, including one with active cooling, will be trialed.

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Catch fittings have been installed to evaluate their thermal and structural performance, and adjustments to the tile line will address hot spots observed on Flight 6. The reentry profile is expected to push the structural limits of Starship’s rear flaps at maximum entry pressure.

SpaceX says lessons from these tests are critical to refining the next-generation Starship and Super Heavy vehicles. With Starfactory production ramping in Texas and new launch infrastructure under development in Florida, the company is pushing to hit its goal of achieving a fully reusable orbital launch system.

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FAA clears SpaceX for Starship Flight 10 after probe into Flight 9 mishap

SpaceX will attempt a Gulf splashdown for Flight 10 once more instead of a tower capture.

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Credit: SpaceX

The Federal Aviation Administration has closed its review of SpaceX’s Starship Flight 9 mishap, clearing the way for the next launch attempt as soon as August 24. 

Flight 9 ended with the loss of both the Super Heavy booster and the upper stage, but regulators accepted SpaceX’s findings that a fuel component failure was the root cause. No public safety concerns were reported from the incident.

Starship recovery lessons

SpaceX noted that Flight 9 marked the first reuse of a Super Heavy booster. Unlike prior attempts, the company did not try a tower “chopsticks” recovery, opting instead for an offshore return that ended in a destructive breakup. The upper stage was also lost over the Indian Ocean. 

As per the FAA in its statement, “There are no reports of public injury or damage to public property. The FAA oversaw and accepted the findings of the SpaceX-led investigation. The final mishap report cites the probable root cause for the loss of the Starship vehicle as a failure of a fuel component. SpaceX identified corrective actions to prevent a reoccurrence of the event.”

SpaceX also highlighted that Flight 9’s debris did not harm any wildlife. “SpaceX works with an experienced global response provider to retrieve any debris that may wash up in South Texas and/or Mexico as a result of Starship flight test operations. During the survey of the expected debris field from the booster, there was no evidence of any floating or deceased marine life that would signal booster debris impact harmed animals in the vicinity,” the private space company noted.

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Expanding test objectives

To mitigate risks, SpaceX plans to adjust return angles for future flights and conduct additional landing burn tests on Flight 10. SpaceX will attempt a Gulf splashdown for Flight 10 once more, instead of a tower capture, according to a report from the Boston Herald.

The upcoming Starship Flight 10, which will be launching from Starbase in Texas, will also mark SpaceX’s attempt to perform its first payload deployment and an in-space Raptor relight. Despite recent setbacks, which include the last three flights ending with the upper stage experiencing a rapid unscheduled disassembly (RUD), Starship remains central to NASA’s Artemis program, with a variant tapped as the human landing system for Artemis III, the first since the Apollo program. 

Standing more than 400 feet tall and generating 16 million pounds of thrust, Starship remains the most powerful rocket flown, though it has yet to complete an orbital mission. The FAA has expanded SpaceX’s license to allow up to 25 Starship flights annually from Texas.

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