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SpaceX operational astronaut launch debut back on track after “nail polish” delay

SpaceX's Crew-1 NASA astronauts pose in front of the Crew Dragon that will ferry them to the International Space Station just days before the spacecraft shipped to Florida. (SpaceX)

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In a new NASA briefing, SpaceX vice president of build and flight reliability Hans Koenigsmann was able to explain in far more detail why a recent last-second Falcon 9 launch abort happened and how it wound up delaying the company’s first operational astronaut launch.

Now scheduled to lift off no earlier than (NET) 7:49 pm EST (00:49 UTC) on Saturday, November 14th, SpaceX’s Crew Dragon Crew-1 mission was originally expected to launch in late September, October 23rd, and October 31st. On October 2nd, however, a new Falcon 9 booster – sibling to Crew-1’s own new booster – automatically aborted its GPS III SV04 satellite launch attempt just two seconds before liftoff. The rare last-second abort was quickly blamed on “unexpected pressure rise in the turbomachinery gas generator” by CEO Elon Musk.

Likely built side-by-side with faulty GPS III SV04 Falcon 9 booster B1062 at SpaceX’s Hawthorne, California factory, Crew-1 Falcon 9 booster B1061 was almost immediately inspected to search for any commonality once the cause of the abort was better understood.

SpaceX COO and President Gwynne Shotwell stands in front of the Falcon 9 booster that will soon ferry four astronauts to the ISS. (TIME/SpaceX)

Just one week before the latest briefing, NASA human spaceflight program administrator and former Commercial Crew Program manager Kathy Lueders revealed in a statement on Twitter that SpaceX was still analyzing the cause of the abort but had already determined that at least one Crew-1 booster engine would need to be replaced, as well as one engine on Falcon 9 booster B1063.

Crew-1 Falcon 9 booster B1061 arrived in Florida on July 14th. (SpaceX)
Falcon 9 booster B1063 was spotted on its way west from McGregor, Texas to Vandenberg Air Force Base, California in August. (D. Stamos)

Now, during NASA’s October 28th Crew-1 briefing, SpaceX’s Koenigsmann revealed that the company had ultimately decided to replace not one but two of Crew-1 booster B1061’s nine Merlin 1D engines. Thanks to Falcon 9’s namesake nine-engine booster design and SpaceX’s prolific rocket factory, that process was completed extraordinarily quickly, simply requiring the redirection of already qualified Merlin 1D engines from a fairly large pool. Based on Koenigsmann’s phrasing, SpaceX has already installed both replacement engines on the Crew-1 booster.

What, though, caused GPS III SV04’s launch abort and how did that affect Crew-1?

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Rocket engine vs. “nail polish”

According to Koenigsmann, in the course of the rapid and complex mechanical and electrical ballet preceding Falcon 9 first stage ignition, the rocket’s autonomous flight computer observed that two of the GPS III SV04 booster’s nine Merlin 1D engines appeared to be running ahead of schedule, so to speak. The computer immediately halted the ignition process to avoid what could have otherwise been a “hard” (i.e. stressful or damaging) start. SpaceX quickly began inspecting the rocket within 24 hours but was unable to detect anything physically or electrically wrong with Falcon 9’s Merlin 1D engines and engine section.

A Merlin 1D engine is inspected and tested in McGregor, Texas. (SpaceX)

Out of an abundance of caution, SpaceX removed both misbehaving engines and shipped them to its McGregor, Texas development and test facilities where – somewhat miraculously – the same premature startup behavior was replicated on the test stand. After a great deal of increasingly granular inspections, SpaceX finally narrowed the likely cause down to a tiny plumbing line feeding one of the engine’s gas generator relief valves. In a seemingly random subset of relatively new Merlin 1D engines, SpaceX eventually discovered that a supplier-provided relief valve line was sometimes clogged by a protective lacquer Koenigsmann likened to “red nail polish.”

A Merlin 1D is prepared at SpaceX’s Hawthorne factory. The small cylindrical tube on the side is the engine’s gas generator. (SpaceX)

Used to selectively exclude parts of the engine tubing during a surface finishing process known as anodization, the lacquer was either unsuccessfully removed on a random selection of engine parts or was accidentally channeled into a blockage by over-enthusiastic cleaning. Ultimately, for whatever, reason that miniscule blockage was enough to cause affected Merlin 1D engines to consistently attempt to ignite a tiny fraction of a second early.

Crucially, when SpaceX discovered the possible cause and cleaned out the blocked plumbing, each previously affected Merlin 1D engine performed perfectly, all but directly confirming both the cause and the cure for Falcon 9’s October 2nd abort.

A Falcon 9 Block 5 booster’s engine section and heat shield. (SpaceX/Discovery)

Astronauts enter quarantine

In anticipation of SpaceX seemingly simple solution to the gas generator problem, NASA Commercial Crew Program manager Steve Stich revealed that SpaceX’s Crew-1 mission astronauts – Shannon Walker, Victor Glover, and Mike Hopkins, and JAXA (Japanese) astronaut Soichi Noguchi – had begun routine prelaunch quarantine procedures in anticipation of a November 14th launch.

NASA astronauts Shannon Walker, Victor Glover, and Mike Hopkins, and JAXA (Japanese) astronaut Soichi Noguchi are nearly set to fly on Crew-1. (SpaceX)
Crew-1 will follow in the fresh footsteps of NASA astronauts Bob Behnken and Doug Hurley’s near-flawless Demo-2 Crew Dragon launch and landing debut. (NASA/Bill Ingalls)

Stich also offered a more specific Crew-1 schedule, beginning with an integrated Falcon 9 and Crew Dragon static fire test NET November 9th and a full dry dress rehearsal on November 11th before the first launch attempt on November 14th. Notably, thanks to coincidental orbital dynamics, a successful launch on November 14th would enable Crew Dragon to raise its orbit and rendezvous with the International Space Station a brisk eight and a half hours after liftoff – three times quicker than the more common 27.5-hour transit.

Stay tuned for updates as the mission’s launch date approaches.

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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 just unlocked sales to 50,000+ government agencies

It marks a significant step in expanding Tesla’s presence in the public sector, where procurement processes have traditionally slowed electric vehicle adoption.

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Credit: Patrick Bean | X

Tesla just unlocked sales to over 50,000 government agencies by entering a new agreement with Sourcewell, a purchasing cooperative.

Tesla entered a new master purchasing agreement with Sourcewell, the largest government purchasing cooperative in the U.S. This will enable streamlined sales of its EVs to more than 50,000 U.S. public entities. Tesla entered Designated Contract 0813525-TES, and the agreement covers Model 3, Model Y, and Cybertruck, and potentially other vehicles the company could release.

It marks a significant step in expanding Tesla’s presence in the public sector, where procurement processes have traditionally slowed electric vehicle adoption.

The deal allows eligible agencies, including cities, school districts, state governments, and higher-education institutions, to purchase Tesla vehicles directly through Sourcewell without conducting their own lengthy competitive bidding or request-for-proposal (RFP) processes.

Pricing is pre-negotiated and capped, providing transparency and predictability. Agencies simply register for a Sourcewell account online or by phone and place orders under the existing contract. This cooperative model aggregates demand across thousands of members, reducing administrative costs and time while ensuring compliance with public procurement rules.

For Tesla, the agreement removes major barriers to government fleet sales. Public-sector procurement cycles often stretch 12 to 18 months due to bidding requirements and committee reviews.

Tesla buyers in the U.S. military can get $1,000 off Cybertruck purchases

By securing the master contract, Tesla gains immediate, simplified access to a massive customer base that previously faced friction in adopting EVs. The company highlighted in its announcement that the partnership will help these 50,000-plus agencies “save thousands of $$$ in operating costs for their vehicle fleet over time” through lower maintenance, energy efficiency, and the elimination of tailpipe emissions.

The initial four-year term runs through November 13, 2029, with options for up to three one-year extensions, offering long-term stability for both parties.

Sourcewell’s role is central to execution. As a cooperative purchasing organization, it negotiates and manages vendor contracts on behalf of its members, then makes them available nationwide. Participating entities contact Tesla’s dedicated fleet team or Sourcewell representatives to complete purchases, bypassing redundant paperwork.

This structure accelerates fleet electrification while maintaining fiscal accountability—agencies receive pre-vetted pricing and terms without reinventing the wheel for each vehicle order.

The partnership positions Tesla to capture a larger share of the public fleet market, where total cost of ownership often favors electric vehicles once procurement hurdles are removed.

For government buyers, it translates to faster deployment of sustainable fleets, reduced long-term expenses, and alignment with environmental mandates. As more agencies transition, the contract could contribute to broader EV infrastructure growth and taxpayer savings across the country.

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Elon Musk

How much of SpaceX will Elon Musk own after IPO will surprise you

SpaceX’s IPO filing confirms Musk will maintain his voting power to make key decisions for the company.

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Rendering of Elon Musk overlooking a Starship fleet (Credit: Grok)

Elon Musk will retain dominant voting control of SpaceX after it goes public, according to the company’s IPO prospectus that was filed with the SEC. The filing reveals a dual-class equity structure giving Class B shareholders 10 votes each, concentrating power with Musk and a handful of other insiders, while Class A shares sold to public investors carry one vote.

Musk holds approximately 42% of SpaceX’s equity and controls roughly 79% of its votes through super-voting shares. He will simultaneously serve as CEO, CTO, and chairman of the nine-member board after the listing. Beyond that, the filing includes provisions that may limit shareholders’ influence over board elections and legal actions, forcing disputes into arbitration and restricting where they can be brought.

The case for Musk holding this level of control is grounded in SpaceX’s actual history. The company’s most important bets, from reusable rockets to a global satellite internet constellation, were decisions that ran against conventional aerospace thinking and would likely have faced resistance from a board accountable to investor gains. Fully reusable rockets were considered economically irrational by established industry players for years. Starlink, which now generates over $4 billion in annual operating profit, was widely dismissed as financially unviable when it was proposed. The argument for concentrated founder control seems straightforward, and the decisions that built SpaceX into what it is today required someone willing to ignore consensus and absorb years of losses.

SpaceX files confidentially for IPO that will rewrite the record books

For context, Musk’s position is significantly more dominant than Zuckerberg’s at Meta. The comparison with Tesla is also worth noting. When Tesla did its IPO in 2010, it did not issue dual-class shares. Musk has only recently pushed for enhanced voting protection, proposing at least 25% control at Tesla in 2024 after selling shares to fund his Twitter acquisition left him with around 13%.

SpaceX has clearly learned from that experience and structured the IPO differently by planning to allocate up to 30% of shares to retail investors, roughly three times the typical norm for a large offering. The roadshow is expected to begin the week of June 8, with a Nasdaq listing rumored to be a $1.75 trillion valuation and a $75 billion raise.

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Tesla bolsters App with new safety, insurance, and storage features

The Tesla Smartphone App is one of the biggest and best features and advantages owners have. Everything from moving the vehicle with Summon, to getting Navigation sent to the car, to preconditioning the cabin can be done with the Tesla App.

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Credit: Tesla

Tesla is bolstering its smartphone App with a series of new features to streamline operations for owners. The new additions include fixes to safety, its in-house insurance offering, and storage management for Dashcam clips.

The Tesla Smartphone App is one of the biggest and best features and advantages owners have. Everything from moving the vehicle with Summon, to getting Navigation sent to the car, to preconditioning the cabin can be done with the Tesla App.

But in classic Tesla fashion, the company is aiming to improve the offerings of the app, and it is doing so with a handful of new features. They were first discovered by Tesla App Updates.

Tesla Insurance – Safety Score 3.0

This is truly part of the Spring 2026 Update, but Tesla has now given more transparency on how FSD has saved people money on their premiums.

Tesla intertwines FSD with in-house Insurance for attractive incentive

Additionally, Tesla is now automatically awarding a Safety Score of 100 for every mile traveled on Full Self-Driving (Supervised).

Update Tracking

Updates traditionally appear on the App or on the Center Touchscreen in the car. There is nothing better than seeing that Green Arrow at the top of the screen, or opening your app and seeing that there is a Software Update available.

Now, there will be no need to manually check the app and initiate the download. Tesla is enabling a new feature that will automatically download updates for you.

Storage Management

Your USB drive can now be remotely formatted, and old Dashcam clips can be deleted straight from the phone. When you record a lot of things using the Dashcam feature, that storage fills up pretty quickly.

Now, manually deleting the Dashcam videos is easier than ever.

Trailer Light Test

This is perhaps the coolest and most crucial addition to the Tesla App, as those who tow and haul will now be able to trigger a diagnostic light sequence from the app while standing behind your trailer to ensure the brake lights work.

Verifying your trailer lights are connected properly and operating normally and as intended is normally a massive hassle.

Now, a new trigger will be available to initiate a diagnostic light sequence directly from your phone.

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