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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) 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)

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SpaceX, Boeing astronaut spacecraft working towards orbital meet-up in 2020

Boeing's Starliner and SpaceX's Crew Dragon spacecraft could potentially meet in orbit at the International Space Station later this year. (Richard Angle)

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According to Boeing’s new Starliner testing plan, the spacecraft could potentially meet SpaceX’s own Crew Dragon astronaut spacecraft in orbit at the International Space Station (ISS) later this year.

Following Starliner’s near-catastrophic December 2019 orbital flight test (OFT), Boeing and NASA have finally announced that – at a minimum – a second uncrewed flight test will have to be completed before the company will be allowed to launch astronauts. According to the Washington Post, Starliner’s return to flight is expected to occur no earlier than October or November 2020, 10 or 11 months after it suffered several major software failures during its first spaceflight. While delays to that flight schedule are incredibly likely, it does mean that there’s a chance that SpaceX’s second crewed Crew Dragon launch could coincide with Starliner’s second orbital mission — a first for the two NASA Commercial Crew Program (CCP) providers.

Just one week before NASA and Boeing revealed plans to refly Starliner’s uncrewed flight test, NASA announced that SpaceX’s first operational Crew Dragon launch now has a full four astronauts assigned to it. Scheduled to launch no earlier than Q4 2020, the spacecraft will carry three NASA astronauts and one Japanese (JAXA) astronaut to the ISS, remaining in orbit for at least six months before returning its crew back to Earth. Now, there’s a chance that SpaceX’s first operational Crew Dragon will be joined in orbit by Boeing’s Starliner spacecraft sometime soon after arriving on station.

An photo of SpaceX’s Crew Dragon spacecraft in orbit. (NASA)
A render of Boeing’s Starliner spacecraft in orbit. (Boeing)

As previously discussed on Teslarati, Boeing’s Starliner OFT suffered several near-catastrophic close calls in the few days it spent in space, all of which appear to have egregiously shoddy and unqualified software to blame.

“Starliner launched atop a ULA Atlas V rocket on its orbital launch debut (OFT) on December 20th, 2019. Atlas V performed flawlessly but immediately after Starliner separated from the rocket, things went very wrong.

Bad software ultimately caused the spacecraft to perform thousands of uncommanded maneuvering thruster burns, depleting a majority of its propellant before Boeing was able to intervene. Starliner managed to place itself in low Earth orbit (LEO), but by then it had nowhere near enough propellant left to rendezvous and dock with the ISS – one of the most crucial purposes of the flight test. Unable to complete that part of the mission, Boeing instead did a few small tests over the course of 48 hours in orbit before commanding the spacecraft’s reentry and landing on December 22nd.

The Starliner spacecraft also reportedly almost suffered a second major software failure just hours before reentry. According to NASA and Boeing comments in a press conference held only after news of that second failure broke, a second Starliner software bug – caught only because the first failure forced Boeing to double-check its code – could have had far more catastrophic consequences. NASA stated that had the second bug not been caught, some of Starliner’s thruster valves would have been frozen, either entirely preventing or severely hampering the spacecraft’s detached trunk from properly maneuvering in orbit. Apparently, that service module (carrying fuel, abort engines, a solar array, and more) could have crashed into the crew module shortly after detaching.”


Teslarati.com — February 11th, 2020

The only sane response was obviously for NASA to require Boeing to successfully complete a second Orbital Flight Test (OFT), a necessary decision the space agency and card-holder was bizarrely hesitant to acknowledge. Now, almost four months after Starliner was nearly lost on its first orbital flight test, NASA and Boeing have finally stated the obvious and confirmed that a second OFT will be required before astronauts can fly on Starliner. Even then, if things go wrong during OFT2 or Boeing completes the mission but still fails to rectify all faults identified by a joint failure investigation, NASA may still delay the spacecraft’s astronaut launch debut.

SpaceX has successfully completed and launched two Crew Dragon spacecraft, one to orbit and back and the other on a successful in-flight abort (IFA) demonstration. A third is scheduled to launch to the space station as early as next month. (NASA/Richard Angle/SpaceX)

SpaceX has undeniably had its own stumbles while developing Crew Dragon, most notably when the first successfully flight-proven spacecraft violently exploded moments before a static fire test in April 2019. SpaceX was able to rectify the responsible design flaws and successfully complete an identical static fire test less than seven months later, followed by a second successful launch less than three months after that. Based on WaPo’s indication that Starliner’s second OFT is scheduled for Q4 2020, Boeing is now anywhere from 12-18 months behind SpaceX with its efforts to launch NASA astronauts to and from the space station. SpaceX successfully completed Crew Dragon’s OFT equivalent in March 2019.

Regardless, if Crew Dragon performs flawlessly during its Demo-2 astronaut launch debut – scheduled no earlier than mid-to-late May – and Boeing’s Starliner OFT2 mission launches on time in Q4 2020, there is a great chance that both spacecraft will be simultaneously docked to the space station. Better circumstances would be unequivocally preferable but it will still mark an important symbolic milestone for NASA’s Commercial Crew Program (CCP) and assured access to the ISS.

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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 has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

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Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

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The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

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How SpaceX Is raising Raptor’s sea-level thrust while holding engine mass steady

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Credit: SpaceX

SpaceX’s Raptor engine family has steadily increased sea-level thrust while simultaneously reducing mass, turning iterative engineering gains into substantially higher performance for the Super Heavy booster. CEO Elon Musk shed more light on how powerful Raptor 4 will be, and it’s pretty crazy.

Raptor 1 delivered 185 metric tons of thrust at roughly 2,080 kilograms, while Raptor 2 raised that to 230 tons while cutting mass to about 1,630 kilograms. SpaceX data for Raptor 3 lists a target of 280 tons at 1,525 kilograms (with further reductions in associated vehicle hardware), while operational flight ratings have been cited near 250 tons.

This morning, Elon Musk stated that Raptor 4 is expected to reach 300 tons of sea-level thrust at roughly the same mass as Raptor 3. Across these versions, thrust has risen by more than 60 percent from the first engines while engine mass has fallen, producing a sharp improvement in thrust-to-weight ratio. This is a true testament to how great SpaceX engineering has been:

With 33 engines on SuperHeavy, the jump from earlier versions to a 300-ton Raptor 4 would produce roughly 9,900 metric tons of total liftoff thrust, nearly three times the Saturn V’s approximately 3,400 metric tons from its five F-1 engines.

This is not just a larger number on a data sheet, either, as sea-level thrust is the force available the moment the vehicle leaves the pad. This is when it is heaviest and still deep in Earth’s gravity well and dense atmosphere.

Higher levels of sea-level thrust directly improves the initial thrust-to-weight ratio of the full stack. A higher ratio produces faster acceleration off the pad, which shortens the time the rocket has to spend fighting gravity, and gravity losses during the first minute or two of the flight are a major drain on total available delta-v. Every second shaved off of that early climb preserves more propellant energy for reaching orbital velocity or for carrying extra payload.

Because Super Heavy’s engine count is constrained by vehicle diameter and packing density, increasing thrust per engine is the most straightforward way to raise total liftoff performance without redesigning the booster structure or design.

The same-mass target for Raptor 4 is equally important. Holding engine mass roughly constant while raising thrust improves the engine’s own thrust-to-weight ratio and reduces the structural and propellant mass fraction that must be carried solely to support the engines.

Earlier Raptor iterations also simplified or eliminated extensive vehicle-side hardware such as heat shields. These gains compound: more force for less installed mass leaves additional capacity for propellant, payload, or operational margins such as engine-out capability.

For Starship’s architecture, the practical effects are large. Greater liftoff thrust supports heavier vehicles, larger propellant loads, and higher payloads to low Earth orbit, figures SpaceX has targeted in the 100-plus-ton reusable range. That capacity underpins orbital refueling, lunar missions, and eventual Mars cargo and crew flights.

Continued growth in sea-level thrust therefore tightens the gap between theoretical rocket performance and the high flight rates and reusability needed to make large-scale space transport practical.

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Tesla Assisted Driving expands to tenth EU country

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Tesla has expanded its Tesla Assisted Driving (TAD) suite to its tenth European country, as Latvia joined a growing list of European Union member states authorizing the company’s advanced driver assistance technology.

Tesla Europe announced this morning that the system is now approved in Latvia, with a software rollout to begin soon.

The approval and rollout follow recognition of a provisional European type approval originally granted by the Netherlands’ RDW authority on April 10.

Latvia’s Road Traffic Safety Directorate (CSDD) evaluated the Dutch documentation, coordinated with the other national authorities, and reviewed updates from Tesla. These included tightened limits on speed offsets, automatic resets of any manual speed adjustments after each trip, and stronger driver monitoring.

In Europe, the feature is marketed as Tesla Assisted Driving after a recent rule change that labeled the name “Full Self-Driving” as misleading.

Tesla starts showing how FSD will change lives in Europe

The system remains an SAE Level 2 driver assistance tool, not unsupervised autonomy. It can control speed, steering, braking, lane changes, and intersections while following a navigation route. Drivers need not keep their hands on the wheel at all times, yet they must continuously monitor the road and be prepared to intervene immediately.

The sequence of EU recognitions began with the Netherlands in April and continued through Lithuania, Estonia, Denmark, Belgium, Slovenia, Czechia, Croatia, and Slovakia. Most have relied on mutual recognition of the single Dutch provisional approval rather than independent national testing.

These national clearances do not yet constitute bloc-wide authorization. An EU-wide decision requires a qualified majority in the Technical Committee on Motor Vehicles: at least 15 of 27 member states representing 65 percent of the EU population. Larger markets, like Germany, France, and Italy, remain under review, and a vote is expected this December.

However, for Latvian Tesla owners with compatible vehicles and software, the imminent rollout expands access to the supervised system while underscoring that attentive human oversight remains essential.

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