News
NASA says SpaceX's Crew Dragon abort test is go for launch on doomed Falcon 9 rocket
NASA has formally given SpaceX permission for Crew Dragon’s second launch – a crucial test flight that should be the last before SpaceX launches NASA astronauts to the International Space Station (ISS) for the first time ever.
Known as its In-Flight Abort (IFA) test, Crew Dragon will attempt to escape a Falcon 9 rocket while airborne, a feat that CEO Elon Musk says will almost certainly destroy the rocket in the process. Technically speaking, NASA and SpaceX completed what is known as a Launch Readiness Review (LRR) sometime on Thursday, allowing SpaceX to proceed with launch preparations. By all accounts, Crew Dragon’s IFA test will likely be one of the most spectacular SpaceX launches ever, given that it is all but guaranteed to result in the intentional in-flight failure of a massive Falcon 9 rocket – “destroyed in Dragon fire” according to Musk.
Thanks to a much smoother launch flow compared to Crew Dragon’s Demo-1 orbital launch debut on Falcon 9, SpaceX’s newest Crew Dragon capsule is scheduled to lift off from Kennedy Space Center Launch Complex 39A (KSC LC-39A) as early as 8 am EST (13:00 UTC), Saturday, January 18th. The In-Flight Abort test will likely be one of Crew Dragon’s most challenging hurdles yet but success would be a major boon for the spacecraft’s demonstrated safety. While both Boeing and SpaceX will ultimately ferry NASA astronauts to and from the ISS, only SpaceX chose to prove Crew Dragon’s in-flight abort capabilities in the real world.
Effectively condemned to destruction to support a greater cause after a productive life, Falcon 9 Block 5 booster B1046 rolled out to Pad 39A – Crew Dragon mounted atop it – on January 16th after successfully performing its last routine static fire on the 11th. As previously discussed on Teslarati, B1046 is the first Falcon 9 Block 5 booster completed by SpaceX and is thus also the oldest flightworthy rocket in the company’s substantial fleet.
“After becoming the first SpaceX booster to launch three times in December 2018, B1046 spent several months at SpaceX’s Hawthorne, CA factory undergoing inspections and refurbishment. At some point, SpaceX assigned the thrice-flown booster to support Crew Dragon’s In-Flight Abort (IFA) test – effectively a death sentence – and shipped the booster to Florida, where it publicly appeared for the first time in months on October 3rd, 2019. Given that four more Falcon 9 boosters have now successfully performed three (or even four) orbital-class launches each, B1046’s now-imminent demise is certainly disappointing but remains extremely pragmatic.”
Teslarati.com — January 15th, 2020
As such, there is arguably no better booster for SpaceX to expend even if its loss is still less satisfying than a successful post-launch landing. In fact, aside from NASA’s prematurely-retired Space Shuttle, the entire history of orbital-class rocketry has effectively operated on the assumption that it’s both normal and necessary for rockets to be almost entirely expendable.
Only by sheer force of will has SpaceX turned that assumption on its head, making the act of expending Falcon 9 or Falcon Heavy boosters feel suddenly morose. Even then, the practice of propulsively landing orbital-class boosters is scarcely four years old, while reusing those boosters has been ongoing for less than three years. As such, B1046’s demise should be enjoyed for what it ultimately is: the spectacular retirement of a rocket that has already helped launch three separate payloads to orbit.
Perhaps even more importantly, B1046’s sacrifice should – if things go as planned – also pave the way for Crew Dragon to launch its first NASA astronauts into orbit just a few months from now. For the test to be successful, however, Crew Dragon will have to perform an extremely precise string of maneuvers – the failure of any one of which could potentially lead to the spacecraft’s destruction.
“Traveling as fast as Mach 2.5 (860 m/s) at an altitude of 28 kilometers (17 mi), Crew Dragon will ignite its abort thrusters and attempt to escape, the very act of which will likely hammer the spacecraft’s windward surfaces with an extra dozen or so metric tons (~25,000 lb) of aerodynamic pressure. Crew Dragon C205 could thus find itself traveling almost Mach 3 (more than a kilometer per second) moments after separating from Falcon 9, eventually reaching an apogee of almost 75 km (45 mi), after which it will reenter the bulk of Earth’s atmosphere and have to deploy an array of parachutes to ensure a gentle Atlantic Ocean splashdown.”
Teslarati.com — January 13th, 2020
Unfortunately, Crew Dragon escaping a supersonic Falcon 9 also means that that same Falcon 9 – basically a thin, flexible tube designed to be as light as possible – will meet a supersonic blast of air the moment Dragon’s SuperDraco abort thrusters ignite. A bit like if a hurricane on all kinds of meteorological steroids just sort of punched a soda can for fun, that airstream will almost certainly obliterate Falcon 9’s sacrificial upper stage into a sort of aluminum snow, quickly revealing – and likely then destroying – B1046’s carbon fiber interstage.
The rest of the thrice-flown Falcon 9 booster is also liable to break up after that supersonic punch. In fact, SpaceX engineers are so confident in B1046’s imminent demise that the booster will have neither landing legs or grid fins come launch. In a best-case scenario, if, against all odds, B1046 survives Dragon’s escape, the intact booster will subsequently impact the Atlantic Ocean at terminal velocity and become a nice, artificial reef off the coast of Florida. Stay tuned for updates from Teslarati and photographers Jamie Groh and Richard Angle as Falcon 9 B1046’s demise inches ever closer.
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News
NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded
NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.
NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.
SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.
We’re excited for Falcon 9 and Dragon to launch @NASA’s Crew-15, 16, and 17 missions to the @Space_Station from Florida https://t.co/Qm16vVK9F3 pic.twitter.com/drg3s7GtuM
— SpaceX (@SpaceX) September 18, 2026
The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.
Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.
Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.
Investor's Corner
New drone video shows Tesla’s Optimus Factory reaching a turning point
New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.
Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.
The Giga Texas Optimus Factory latest update … construction keeps moving fast!
Steel assembly is now only about 5 column grids from the north perimeter beam. Concrete is going in on the three upper floors, rebar is still being laid for more pours, and footing / grade-beam work… pic.twitter.com/qvFPvwnYzW
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) September 17, 2026
Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.
Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.
Tesla Giga Texas to feature massive Optimus V4 production line
The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.
Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.
Investor's Corner
Tesla and SpaceX take “Terafab” Trademark fight to Federal Court
Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.
Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.
The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.
What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.
Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry
By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.
TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.
Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.
The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.
NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded
New drone video shows Tesla’s Optimus Factory reaching a turning point
