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NASA says that a minor accident that destroyed a crucial Crew Dragon mockup on March 24th should have minimal impact on the spacecraft's astronaut launch debut. (Richard Angle) NASA says that a minor accident that destroyed a crucial Crew Dragon mockup on March 24th should have minimal impact on the spacecraft's astronaut launch debut. (Richard Angle)

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NASA has good news after SpaceX Crew Dragon parachute test accident

NASA says that a minor accident that destroyed a crucial Crew Dragon mockup on March 24th should have minimal impact on the spacecraft's astronaut launch debut. (Richard Angle)

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NASA has good news after SpaceX suffered an accident that destroyed a Crew Dragon mockup before it could complete a parachute test, indicating that the anomaly could have minimal impact on the spacecraft’s Demo-2 astronaut launch debut.

According to NASA, SpaceX and the space agency are still working to launch astronauts on Crew Dragon as early as “mid-to-late May”. While two recent challenges – the loss of the spacecraft’s most important parachute testing mockup and an unrelated in-flight rocket engine failure – could both singlehandedly delay Demo-2 in certain scenarios, NASA continues to state that a May timeframe is still in the cards. This is an excellent sign that both issues – as previously speculated on Teslarati – are probably much less of a problem than they otherwise could be.

As of now, all Demo-2 hardware – including Falcon 9 booster B1058, a new Falcon upper stage, Crew Dragon capsule C206, and an expendable Dragon trunk – are all believed to be in Florida and technically ready for flight. Waiting for launch at and around Kennedy Space Center (KSC) Launch Complex 39A, the long straw for SpaceX’s inaugural astronaut launch is most likely the completion of formal paperwork and reviews, most of which must be done primarily by NASA employees. SpaceX’s latest technical challenges certainly toss some uncertainty into the mix and serve as a reminder that nothing can or should be taken for granted in human spaceflight but on the whole, there is reason for optimism.

SpaceX began a final round of Crew Dragon parachute testing in January 2020 after a string of successes in Q4 2019. The capsule mockup pictured above was unfortunately destroyed during a helicopter-related incident in March. (SpaceX)

“To date, SpaceX has completed 24 tests of its upgraded Mark 3 parachute design they are working to certify for use on the Crew Dragon spacecraft that will fly NASA astronauts to the International Space Station. The system was used during the SpaceX in-flight abort test in January.

On March 24, SpaceX lost a spacecraft-like device used to test the Crew Dragon Mark 3 parachute design. The test requires a helicopter to lift the device suspended underneath it to reach the needed test parameters. However, the pilot proactively dropped the device in an abundance of caution to protect the test crew as the test device became unstable underneath the helicopter. At the time of the release, the testing device was not armed, and a test of the parachute design was not performed.

Although losing a test device is never a desired outcome, NASA and SpaceX always will prioritize the safety of our teams over hardware. We are looking at the parachute testing plan now and all the data we already have to determine the next steps ahead of flying the upcoming Demo-2 flight test in the mid-to-late May timeframe.”


NASA.gov — March 26th, 2020

While the challenges SpaceX and NASA still have to surmount are thus significant, it’s safe to say that Crew Dragon’s track record more than earns it some optimism as the spacecraft nears the T-1 month mark for what will arguably SpaceX’s most significant launch ever.

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Following a successful Pad Abort test in May 2015, the company spent several years working head down. In mid-2018, SpaceX’s first finished Crew Dragon spacecraft successfully passed through electromagnetic interference (EMI) and thermal vacuum (TVac) testing, arriving at the launch site for preflight processing by July. Unfortunately, for unknown reasons, it took more than half a year more for NASA to finally permit Crew Dragon to launch.

A month and a half after completing an integrated static fire test at Pad 39A, Falcon 9 and Crew Dragon lifted off for the first time ever on March 2nd, 2019. A flawless launch was followed by an equally flawless International Space Station (ISS) rendezvous and docking, completed autonomously and without issue on SpaceX’s first try. Crew Dragon capsule C201 spent five days at the station before autonomously departing, reentering Earth’s atmosphere, and gently splashing down in the Atlantic Ocean under four healthy parachutes.

Altogether, Crew Dragon’s orbital launch debut was such a flawless success that SpaceX’s own director of Crew Dragon mission management stated that he could barely believe how perfectly it went – likely expecting at least something to go slightly awry. That near-perfection certainly didn’t come easily for SpaceX. Boeing – NASA’s second Commercial Crew Program (CCP) partner – has had a far rougher go of things despite the fact that the company does technically have extensive experience building aircraft and rockets.

Boeing’s unfortunate Starliner struggles help to emphasize just how strong SpaceX’s current standing really is. (Richard Angle)

In November 2019, Boeing completed Starliner’s first fully integrated ‘flight’ test in the form of a pad abort. While the spacecraft was able to perform a soft landing, mishandling and bad quality control caused one of its three main parachutes to fail to deploy in an unintentional stress test. A little over a month later, a separate Starliner spacecraft performed its inaugural orbital launch on a ULA Atlas V rocket. From the moment Starliner separated from Atlas V, things began to go wrong. It would ultimately become clear that extremely shoddy software and an almost nonexistent integrated testing regime caused the spacecraft to waste most of its propellant and resulted in an extremely delayed orbital insertion.

While NASA and Boeing both managed to forget a second partial failure until media reporting shed light on it months later, it also turned out that another entirely separate instance of incomplete software may have nearly destroyed Starliner a matter of hours before it was scheduled to reenter Earth’s atmosphere. The spacecraft was ultimately prevented from even attempting a space station rendezvous, one of the major purposes of the test flight.

Falcon 9 B1046 lifted off for the fourth and final time on January 19th, sacrificed so its Crew Dragon payload could perform a flawless in-flight abort (IFA) test. (Richard Angle)
Crew Dragon lifted off on a Falcon 9 rocket for the second time ever on January 19th, 2020. (Richard Angle)
The Dragon In-Flight Abort (IFA) test that followed is believed to have gone exactly as planned. Left up to providers by NASA, Boeing decided early on not to perform a similar real-world Starliner IFA test. (SpaceX)

In simpler terms, Crew Dragon – even with the challenges it has and will soon face – is just shy of primed and ready for flight. As always, it’s better to be safe (and late) than sorry in human spaceflight, particularly the first such mission for SpaceX, but it’s looking increasingly likely that Crew Dragon will be on the launch pad and preparing to lift off with NASA astronauts just two or so months from now.

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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 already has a complete Robotaxi model, and it doesn’t depend on passenger count

That scenario was discussed during the company’s Q4 and FY 2025 earnings call, when executives explained why the majority of Robotaxi rides will only involve one or two people.

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Credit: @AdanGuajardo/X

Tesla already has the pieces in place for a full Robotaxi service that works regardless of passenger count, even if the backbone of the program is a small autonomous two-seater. 

That scenario was discussed during the company’s Q4 and FY 2025 earnings call, when executives explained why the majority of Robotaxi rides will only involve one or two people.

Two-seat Cybercabs make perfect sense

During the Q&A portion of the call, Tesla Vice President of Vehicle Engineering Lars Moravy pointed out that more than 90% of vehicle miles traveled today involve two or fewer passengers. This, the executive noted, directly informed the design of the Cybercab. 

“Autonomy and Cybercab are going to change the global market size and mix quite significantly. I think that’s quite obvious. General transportation is going to be better served by autonomy as it will be safer and cheaper. Over 90% of vehicle miles traveled are with two or fewer passengers now. This is why we designed Cybercab that way,” Moravy said. 

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Elon Musk expanded on the point, emphasizing that there is no fallback for Tesla’s bet on the Cybercab’s autonomous design. He reiterated that the autonomous two seater’s production is expected to start in April and noted that, over time, Tesla expects to produce far more Cybercabs than all of its other vehicles combined.

“Just to add to what Lars said there. The point that Lars made, which is that 90% of miles driven are with one or two passengers or one or two occupants, essentially, is a very important one… So this is clearly, there’s no fallback mechanism here. It’s like this car either drives itself or it does not drive… We would expect over time to make far more CyberCabs than all of our other vehicles combined. Given that 90% of distance driven or distance being distance traveled exactly, no longer driving, is one or two people,” Musk said. 

Tesla’s robotaxi lineup is already here

The more interesting takeaway from the Q4 and FY 2025 earnings call is the fact that Tesla does not need the Cybercab to serve every possible passenger scenario, simply because the company already has a functional Robotaxi model that scales by vehicle type.

The Cybercab will handle the bulk of the Robotaxi network’s trips, but for groups that need three or four seats, the Model Y fills that role. For higher-end or larger-family use cases, the extended-wheelbase Model Y L could cover five or six occupants, provided that Elon Musk greenlights the vehicle for North America. And for even larger groups or commercial transport, Tesla has already unveiled the Robovan, which could seat over ten people.

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Rather than forcing one vehicle to satisfy every use case, Tesla’s approach mirrors how transportation works today. Different vehicles will be used for different needs, while unifying everything under a single autonomous software and fleet platform.

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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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