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NASA is training SpaceX's first Crew Dragon astronauts for a much longer mission in space

Crew Dragon completes one of its last tests before its astronaut launch debut, February 2020. (SpaceX)

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NASA has revealed that the astronauts assigned to SpaceX’s Crew Dragon astronaut launch debut are training for a space station mission many times longer than initially planned.

Scheduled to deliver two NASA astronauts to and from the International Space Station (ISS) no earlier than (NET) late-April or May 2020, Crew Dragon’s Demo-2 mission will be the first crewed launch in SpaceX’s 18-year history. As previously noted on Teslarati (and by NASA itself, briefly), Demo-2 will also mark the first time in history that a privately-built spacecraft attempts to launch humans into orbit.

Still, NASA has funded the development of Crew Dragon (and competitor Boeing’s Starliner) not to achieve firsts but to restore the United States’ ability to launch its own astronauts to the ISS. Along those lines, both Crew Dragon (Demo-2) and Starliner’s (CFT) astronaut test flights were nominally designed to last about a week or two before returning NASA’s astronauts to Earth – a full end-to-end test for both extraordinarily complex vehicles. Two weeks, however, is simply not long enough for those astronauts to practically serve as full members of space station crew, something the ISS generally requires. In response, NASA has been seriously considering extending Boeing’s crewed test flight and has just recently suggested that SpaceX’s own Demo-2 test flight will be similarly upgraded.

About a month ago, SpaceX and NASA talked openly about the possibility of a longer-duration Crew Dragon astronaut launch debut for the first time, potentially extending the amount of time those astronauts are able to spend at the space station from about one week up to 1.5-3 months. This would allow Crew Dragon’s Demo-2 NASA astronauts – Bob Behnken and Doug Hurley – to serve as full members of the ISS crew, expanding the US presence from one to three astronauts.

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Ars Technica’s Eric Berger offered some additional details about what exactly NASA might task Behnken and Hurley with on an extended flight earlier this month. Most importantly, the space agency wants the former astronaut – a Space Shuttle and extra-vehicular activity (EVA) veteran – to be (re)trained for spacewalks, allowing him to support an ever-growing to-do list of critical space station repairs and upgrades.

The International Space Station is pictured in October 2018 during a crewed Soyuz fly-around. (NASA/Roscosmos)

In effect, extending Crew Dragon’s astronaut flight test will make it almost identical to an “operational” flight where Crew Dragon ferries astronauts to the space station, docks for about six months, and finally returns the same astronauts to Earth at the end of its mission. More importantly, though, NASA’s decision to extend Commercial Crew Program (CCP) test flights – kickstarted with Boeing’s beleaguered Starliner spacecraft – is motivated by a desire to prevent the United States’ presence on the space station from dwindling or even regressing to zero in the near future.

Triggered by years of SpaceX and Boeing delays, NASA will now likely have to purchase more seats on Russian Soyuz launches if it wishes to maintain an full, uninterrupted presence on ISS for the next 12-24 months. After suffering numerous deeply concerning software failures on its first and only orbital launch, Boeing’s Starliner is unlikely to be ready to launch crew anytime soon. At the same time, although SpaceX is closer to its astronaut launch debut than ever before, it’s highly unlikely that Crew Dragon can singlehandedly support a full ISS complement of three NASA astronauts while Starliner works out its issues.

Boeing’s Starliner and SpaceX’s Crew Dragon spacecraft stand vertical at their respective launch pads in December 2019 and January 2020. Crew Dragon has now performed two successful full-up launches to Starliner’s lone partial failure. (Richard Angle)

As such, NASA is looking everywhere it can to squeeze a bit more on-orbit time out of existing astronaut missions scheduled in the next year or so, and both Starliner and Crew Dragon’s test flights – barring showstoppers – are excellent opportunities. With NASA Johnson Space Center’s confirmation that both Behnken and Hurley are already deep into the extra training needed for an extended flight, chances are good that both astronauts will be ready for a one- or several-month mission by the time that NASA and SpaceX are ready and willing to launch.

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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 spotted with interesting charging solution, stimulating discussion

The port is located in the rear of the vehicle and features a manual door and latch for plug-in, and the video shows an employee connecting to a Tesla Supercharger.

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Credit: What's Inside | X

Tesla Cybercab units are being tested publicly on roads throughout various areas of the United States, and a recent sighting of the vehicle’s charging port has certainly stimulated some discussions throughout the community.

The Cybercab is geared toward being a fully-autonomous vehicle, void of a steering wheel or pedals, only operating with the use of the Full Self-Driving suite. Everything from the driving itself to the charging to the cleaning is intended to be operated autonomously.

But a recent sighting of the vehicle has incited some speculation as to whether the vehicle might have some manual features, which would make sense, but let’s take a look:

The port is located in the rear of the vehicle and features a manual door and latch for plug-in, and the video shows an employee connecting to a Tesla Supercharger.

Now, it is important to remember these are prototype vehicles, and not the final product. Additionally, Tesla has said it plans to introduce wireless induction charging in the future, but it is not currently available, so these units need to have some ability to charge.

However, there are some arguments for a charging system like this, especially as the operation of the Cybercab begins after production starts, which is scheduled for April.

Wireless for Operation, Wired for Downtime

It seems ideal to use induction charging when the Cybercab is in operation. As it is for most Tesla owners taking roadtrips, Supercharging stops are only a few minutes long for the most part.

The Cybercab would benefit from more frequent Supercharging stops in between rides while it is operating a ride-sharing program.

Tesla wireless charging patent revealed ahead of Robotaxi unveiling event

However, when the vehicle rolls back to its hub for cleaning and maintenance, standard charging, where it is plugged into a charger of some kind, seems more ideal.

In the 45-minutes that the car is being cleaned and is having maintenance, it could be fully charged and ready for another full shift of rides, grabbing a few miles of range with induction charging when it’s out and about.

Induction Charging Challenges

Induction charging is still something that presents many challenges for companies that use it for anything, including things as trivial as charging cell phones.

While it is convenient, a lot of the charge is lost during heat transfer, which is something that is common with wireless charging solutions. Even in Teslas, the wireless charging mat present in its vehicles has been a common complaint among owners, so much so that the company recently included a feature to turn them off.

Production Timing and Potential Challenges

With Tesla planning to begin Cybercab production in April, the real challenge with the induction charging is whether the company can develop an effective wireless apparatus in that short time frame.

It has been in development for several years, but solving the issue with heat and energy loss is something that is not an easy task.

In the short-term, Tesla could utilize this port for normal Supercharging operation on the Cybercab. Eventually, it could be phased out as induction charging proves to be a more effective and convenient option.

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Tesla confirms that it finally solved its 4680 battery’s dry cathode process

The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.

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tesla 4680
Image used with permission for Teslarati. (Credit: Tom Cross)

Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years. 

The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.

Dry cathode 4680 cells

In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.

The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”

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Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.

4680 packs for Model Y

Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla: 

“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”

The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.

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Tesla Giga Texas to feature massive Optimus V4 production line

This suggests that while the first Optimus line will be set up in the Fremont Factory, the real ramp of Optimus’ production will happen in Giga Texas.

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Credit: Tesla/YouTube

Tesla will build Optimus 4 in Giga Texas, and its production line will be massive. This was, at least, as per recent comments by CEO Elon Musk on social media platform X.  

Optimus 4 production

In response to a post on X which expressed surprise that Optimus will be produced in California, Musk stated that “Optimus 4 will be built in Texas at much higher volume.” This suggests that while the first Optimus line will be set up in the Fremont Factory, and while the line itself will be capable of producing 1 million humanoid robots per year, the real ramp of Optimus’ production will happen in Giga Texas. 

This was not the first time that Elon Musk shared his plans for Optimus’ production at Gigafactory Texas. During the 2025 Annual Shareholder Meeting, he stated that Giga Texas’ Optimus line will produce 10 million units of the humanoid robot per year. He did not, however, state at the time that Giga Texas would produce Optimus V4. 

“So we’re going to launch on the fastest production ramp of any product of any large complex manufactured product ever, starting with building a one-million-unit production line in Fremont. And that’s Line one. And then a ten million unit per year production line here,” Musk stated. 

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How big Optimus could become

During Tesla’s Q4 and FY 2025 earnings call, Musk offered additional context on the potential of Optimus. While he stated that the ramp of Optimus’ production will be deliberate at first, the humanoid robot itself will have the potential to change the world. 

“Optimus really will be a general-purpose robot that can learn by observing human behavior. You can demonstrate a task or verbally describe a task or show it a task. Even show it a video, it will be able to do that task. It’s going to be a very capable robot. I think long-term Optimus will have a very significant impact on the US GDP. 

“It will actually move the needle on US GDP significantly. In conclusion, there are still many who doubt our ambitions for creating amazing abundance. We are confident it can be done, and we are making the right moves technologically to ensure that it does. Tesla, Inc. has never been a company to shy away from solving the hardest problems,” Musk stated. 

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