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SpaceX, NASA schedule back-to-back astronaut recovery and launch after delays

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Poor winter weather on Florida’s East Coast and across the Atlantic Ocean has forced NASA and SpaceX to flip the nominal sequence of events for the imminent back-to-back launch and recovery of two Crew Dragons.

Contrary to preference, SpaceX and NASA’s four Crew-2 astronauts are now scheduled to undock from the International Space Station (ISS) and return to Earth before their replacements (Crew-3) launch to the station. As a result, there will be no on-orbit handoff, meaning that only one NASA astronaut – Mark Vande Hei – will be left alongside cosmonauts Anton Shkaplerov and Pyotr Dubrov to crew and operate the US segment of the ISS until Crew-3’s arrival.

After several delays from an initial October 30th target, Crew-3 astronauts Raja Chari, Thomas Marshburn, Matthias Maurer, and Kayla Barron are scheduled to ride Falcon 9 and Crew Dragon to orbit no earlier than (NET) 9:03pm EST, Wednesday, November 10th (02:03 UTC 13 Nov) – two days after Crew-2 is expected to splash down.

Crew-3 astronauts Matthias Maurer, Thomas Marshburn, Raja Chari, and Kayla Barron have been (mostly) ready for flight since late October. (SpaceX)

Save for a one-day delay from October 30th to October 31st needed to give SpaceX and NASA time to qualify a fixed plumbing leak for crewed spaceflight, all subsequent delays into November have been caused by poor weather – a rather common late fall and winter occurrence in the Atlantic Ocean and southern US. The weather isn’t entirely to blame, though. Crew Dragon, SpaceX, and NASA are also partly responsible due to the extremely strict and narrow range of weather conditions the spacecraft has been certified to operate in.

Worse, a large portion of Dragon’s weather constraints are for hypothetical abort scenarios rather than the nominal launch – not “is it safe to launch?” but “is it safe to launch if something fails catastrophically and Dragon aborts and has to splash down anywhere in a several-dozen-mile corridor stretching the entire length of the Atlantic?” In the case of Crew-3’s launch, the main condition making that vast abort zone a no-go for launch is surface winds.

While aborting an expensive, time-sensitive rocket launch due to ground winds might bring to mind some kind of storm with vast swells and torrential rain, the reality is that NASA has only rated Crew Dragon to splash down when surface winds are less than 8-11 mph (13-18 km/h). In other words, the conditions causing 10+ days of delays and leading NASA to leave a skeleton crew at the space station’s US segment amounts to a firm breeze. There are likely many reasons (most hopefully good) for that highly conservative limit but ultimately, it means that NASA’s Crew Dragon missions will almost always be at risk of weather delays both going up and coming down.

Crew-2 astronauts Shane Kimbrough, Megan McArthur, Akihiko Hoshide, and Thomas Pesquet check out their Dragon ahead of one last ride home. (Thomas Pesquet)

As if to emphasize that fact, winds in the Gulf of Mexico, on the opposite side of Florida, also caused NASA to delay SpaceX’s Crew-2 departure and splashdown from November 6th/7th to November 8th, raising the risk of more Crew-3 delays or another complex schedule conflict if conditions force another change. A minor issue with Dragon’s toilet discovered during Inspiration4 and fixed on Crew-3’s ride to space will preclude its use during Crew-2’s 11-hour trip home, but that change should be barely noticeable to professional astronauts that are required to wear diapers as a precaution regardless. Otherwise, throughout the delays, Falcon 9 B1067, Crew-3 Dragon C210, and Crew-2 Dragon C206 have all thankfully remained healthy and ready to go.

Crew-2 is scheduled to undock from the ISS around 2pm EST (17:00 UTC) on November 8th and could splash down as early as 10:33 pm (03:33 UTC) – less than nine hours later.

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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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Cybertruck

Tesla Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Elon Musk

Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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Elon Musk

SpaceX has solved Starship’s biggest challenge, Elon Musk says

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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