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SpaceX’s historic NASA astronaut launch debut on track for second attempt

An ominous shelf cloud rolls over Kennedy Space Center and LC-39A on Wed. May 27th during the first launch attempt of SpaceX's Demo-2. (Credit: Richard Angle for Teslarati)

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Rather than making history on May 27th, SpaceX’s highest-profile launch ever – Crew Dragon’s NASA astronaut launch debut – was scrubbed just minutes before liftoff by stormy Florida weather. Unfortunately, conditions appear to be even less favorable on Saturday and Sunday backup windows.

Weather trended well, until it didn’t

The day began with launch fans growing increasingly concerned about a system of low-pressure off of Florida’s northeast coast that strengthened into tropical storm Bertha – the second named storm before the official start of the Atlantic basin hurricane season on June 1st. As the day progressed, Bertha became less of a worry for SpaceX recovery and emergency abort drop zones as it moved further north up the coast eventually making landfall in South Carolina. Then the thunderstorms began firing up.

Hans Koenigsmann, vice president for build and flight reliability at SpaceX, looks at a monitor showing a live feed of a SpaceX Falcon 9 rocket carrying the company’s Crew Dragon spacecraft on the launch pad during the countdown for a launch attempt of NASA’s SpaceX Demo-2 mission. (Credit: NASA/Joel Kowsky)

Going into launch day launch weather officer, Mike McAleenan of the U.S. Space Force’s 45th Weather Squadron predicted a 60% chance of favorable launch weather conditions. That decreased slightly to 50% during the morning’s launch weather briefing. The 50/50 shot of Florida weather cooperating to get the launch off during the one-second long launch window opportunity remained the main concern for the rest of the day.

An ominous thunderstorm rolls over LC-39A ahead of SpaceX’s ultimately scrubbed first attempt to launch the Crew Dragon Demo-2 test flight on Wednesday, May 27th. (Credit: Richard Angle for Teslarati)

During the final thirty minutes of the countdown, many of the weather constraints that were holding up a green-light for launch from cleared up, but one last weather rule remained no-go. McAleenan stated over the internal weather communication loop during NASA’s live broadcast that if the launch window could’ve extended another 10 minutes, the weather would probably cooperate. This wasn’t the case, though. The launch attempt was ultimately aborted just 14 minutes shy of liftoff due to the “field mill” rule not clearing in time. The lightning field mill rule refers to a sophisticated electrical field system that spans the entire area of Kennedy Space Center and the surrounding area of Cape Canaveral responsible for continuously detecting the electrical charge of the atmosphere.

Protecting rockets from producing lightning

Rockets are not permitted to launch through an electrically charged atmosphere because of the possibility of what is called “triggered” lightning – lightning that is actually produced by a rocket bursting through an electrically charged atmosphere. Sending a rocket through an already unstable atmosphere can cause a disturbance, a lightning bolt, to be triggered. This phenomenon has the capability of being potentially dangerous for the rocket and, more importantly in this case, the occupants on board.

A very helpful infographic published by the 45th Weather Squadron regarding the natural and triggered lightning launch rules. (Credit: 45th Weather Squadron)

Demo-2, Round 2

Following a scrubbed first attempt, the 45th Weather Squadron released the L-3 (3 days until launch) forecast for the second attempt to send NASA astronauts Doug Hurley and Bob Behnken to the International Space Station. The prediction looked much like the one going into Wednesday’s attempt. On Thursday morning, May 28th, a new L-2 (2 days until launch) forecast was released showing very little change from the evening before.

SpaceX’s next attempt at a Demo-2 launch will occur on Saturday, May 30th, at 3:22:41pm EDT with another backup attempt scheduled for Sunday, May 31st at 3:00:07pm EDT. The outlook for the weather, however, looks much the same as it did for Wednesday. The 45th Weather Squadron is currently predicting only a 40% chance of favorable launching conditions on both days, and that’s just for the weather directly over LC-39A at the time of launch.

A L-3 weather forcast provided by the U.S. Space Force’s 45th Weather Squadron outlines a 40% chance of acceptable weather conditions at time of launch for SpaceX’s back-up attempt to lauch the first ever crewed mission, Demo-2, on Saturday, May 30th. (Credt: U.S. Space Force – 45th Weather Squadron)

The 45th Weather Squadron does not predict other conditions that can determine a scrub of launch including upper-level atmospheric winds capable of completely sheering apart a rocket at altitude, or weather conditions for booster recovery and the recovery zones needed to rescue the Dragon capsule in the event of an emergency abort scenario. SpaceX has its own team of professionals that work in tandem with the 45th Weather Squadron to monitor the conditions of the recovery and abort zones. SpaceX takes things into consideration like wave height and patterns to determine whether or not conditions are appropriate enough for crews to perform any and all recovery operations that may be needed.

For Saturday’s attempt, the SpaceX Demo-2 will once again face the challenges of precipitation and dangerous lightning producing anvil and cumulus clouds. Expect launch day to look much like it did during the first attempt on Wednesday. SpaceX will need to thread one seriously precise needle to pull off the most historic rocket launch in company history.

Check out Teslarati’s newsletters for prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket launch and recovery processes.

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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.

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SpaceX Terafab rendering

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.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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Investor's Corner

Tesla uber bull Ron Baron says ‘the time to buy the stock is now’

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Credit: Tesla

In a new interview on Wednesday, Tesla uber bull Ron Baron said that anyone looking to buy the company’s stock should do so as soon as they can.

Baron, founder and CEO of Baron Capital and one of Tesla’s most persistent institutional bulls, used a CNBC Squawk Box appearance on Wednesday to deliver a familiar message with fresh urgency: In his opinion, Tesla stock is a buy:

“The time to buy the stock is now. FSD is catching on, and it’s going to be bigger and bigger. 55% of new buyers are buying it (Teslas) with FSD. It’s going to be everywhere. It’s safer.”

The Baron Capital frontman’s case is built around Full Self-Driving. Tesla reported 1.48 million active FSD subscriptions in the second quarter, up 56 percent year over year, and company officials have said roughly 55 percent of new North American deliveries left with a subscription enabled.

Baron framed that attach rate as proof the product is moving from enthusiast extra to default expectation, and as a reason software, not just vehicle volume, should drive the next phase of value.

His conviction on Tesla shares is not theoretical, as Baron Capital made its first Tesla investment in 2014, after years of meetings that began around the 2010 IPO roadshow. The firm later built a large SpaceX position starting in 2017.

Baron said those Musk-led bets have generated about $30 billion of the $71 billion in profits Baron Capital has produced for clients. He put the firm’s current exposure at roughly $25 billion in SpaceX and $5 billion in Tesla. Personally, he described SpaceX as his largest holding, at about $5 billion, with about $1.5 billion in Tesla and additional Tesla exposure through the firm’s funds.

That concentration is also a statement of loyalty. Asked about talk of a SpaceX-Tesla combination, Baron said he had already walked Elon Musk through arguments for and against a deal, then declined to repeat them on air. His public position was simpler: “Whatever you decide is better is what I’m going to support,” he said to Musk.

Baron also said that he picked up the farewell edition of the Model S after Tesla decided to sunset the vehicle earlier this year, calling it his favorite car he’s ever driven.

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