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SpaceX’s Crew Dragon preps for debut as race to return astronauts to US craft nears final stages

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After spending two weeks testing in a specialized NASA-run facility, SpaceX’s first flightworthy Crew Dragon spacecraft was shipped from Ohio to Florida, where it will now spend a number of months preparing for its first (uncrewed) launch into Earth orbit.

Known as Demonstration Mission 1 (DM-1), this critical milestone must be passed before the capsule will be certified to carry NASA astronauts to the International Space Station (ISS) sometime in 2019. While DM-1 will not sport a human crew, the spacecraft is nevertheless expected to demonstrate all life and mission-critical components, ranging from Crew Dragon’s complex array of avionics and ground/orbital communications equipment to craft’s ability to safely return passengers to Earth with a soft ocean landing.

SpaceX’s Crew Dragon spacecraft has been in the serious hardware development phase for approximately five years, although the concept itself dates back about as early as its Cargo Dragon predecessor – 2005 to 2006, publicly. Over the course of roughly two weeks of testing at NASA’s Plum Brook Station, Crew Dragon was likely subjected to a suite of environmental conditions the spacecraft will need to routinely survive to make it through initial launch and successfully operate under the rigors of microgravity and thermal vacuum conditions.

Given the DM-1 capsule and trunk’s fairly quick jaunt at the huge Plum Brook vacuum chamber and equally quick arrival in Florida, those test results were likely quite favorable. Still, a major amount of work lies ahead before the first full Crew Dragon is ready for its launch atop Falcon 9. Most significantly, the craft’s trunk did not follow its fellow capsule to Florida, but rather returned to SpaceX’s Hawthorne, CA factory to be outfitted with critical flight hardware, particularly radiators and solar arrays. Once that outfit is complete, the module will also be shipped to Florida before being integrated with the DM-1 Crew Dragon capsule.

Of note, the DM-1 capsule has been constructed from the start to support a plan to use the vehicle in an in-flight abort test meant to ensure that the craft can wrest its passengers from harm’s way even at the most intense point of launch, where aerodynamic pressures are at their peak. In order to properly support both the DM-1 orbital mission and the in-flight abort test to follow, the capsule has been outfitted with a fair amount (hundreds of pounds) of hardware that will be unique to the pathfinder spacecraft. This understandably adds its own complexity to the already intense program’s first orbital mission, although it will hopefully not translate into additional delays.

SpaceX competitor’s crewed spacecraft and rocket take shape

It’s worth noting that SpaceX is effectively operating at a distinct – albeit partially self-wrought – financial handicap when compared with Boeing’s Starliner spacecraft program, one of two vehicles funded by NASA to accomplish the same task of safely and reliably transporting astronauts to and from the ISS.

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“NASA awarded firm-fixed-price contracts in 2014 to Boeing and Space Exploration Technologies Corporation (SpaceX) [of] up to $4.2 billion [for Boeing] and $2.6 billion [for SpaceX] for the development of crew transportation systems.” (GAO-18-476)

 

In other words, Boeing requested and received a full 60% more than SpaceX to – quite literally – accomplish an identical task. Alongside the storied and brutally expensive history of crewed American spaceflight, both contracts are an absolute steal for two modernized, crew-capable spacecraft, but a 60% premium is a 60% premium. Foreseeable but slight cost overruns caused, among other things, by additional contractual requirements from NASA have followed a similar trend, roughly proportional to each company’s slice of the original $6.8b Commercial Crew contract.

“As of April 2018, NASA requirement changes had increased the value of contract line item 001 for Boeing by approximately $191 million and for SpaceX by approximately $91 million.” (GAO-18-476)

Still, Boeing’s progress towards its own DM-1 and DM-2 demo flights and a pad-abort test are impressive, although it very likely is more of a demonstration of a different approach to public communications than of any actual step up on SpaceX. In the last few weeks, Boeing has released a number of photos showing off the progress made building its own Starliner capsules and service modules (trunks), three of which are currently in varied states of assembly and integration in the company’s Florida-based facility. Additionally, United Launch Alliance CEO Tory Bruno has shared off-and-on updates and photos of the launch contractor’s own progress assembling the rockets that will launch Boeing’s spacecraft.

Regardless, a huge amount of work lies ahead before both Boeing and SpaceX’s crewed spacecraft are able to conduct their first uncrewed and crewed launches into orbit. Now very outdated, NASA has stated several times recently that the presently available targets of NET August 31 will likely be updated later this month, pushing DM-1 debuts into NET Q4 2018 and the first commercial crewed demo missions to 2019.

Stay tuned, as the Block 5 Falcon 9 tasked with launching SpaceX’s own DM-1 Crew Dragon will likely be the next of a recent flood of finished rockets to leave the company’s Hawthorne factory, where it will head to McGregor, Texas to complete acceptance wet dress rehearsals and static fire tests before shipping to SpaceX’s Pad 39A in Florida.

Follow us for live updates, peeks behind the scenes, and photos from Teslarati’s East and West Coast photographers.

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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 puts Giga Berlin in Plaid Mode with new massive investment

The facility, Tesla’s first in Europe, opened in 2022 and has become a cornerstone for Model Y production and, increasingly, in-house battery manufacturing. Recent announcements highlight a dual focus on scaling vehicle output and advancing vertical integration through 4680 battery cells.

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Credit: Tesla

Tesla is pushing forward with significant upgrades at its Gigafactory Berlin-Brandenburg in Grünheide, Germany, signaling renewed confidence in its European operations despite past market challenges.

The facility, Tesla’s first in Europe, opened in 2022 and has become a cornerstone for Model Y production and, increasingly, in-house battery manufacturing. Recent announcements highlight a dual focus on scaling vehicle output and advancing vertical integration through 4680 battery cells.

In April, plant manager André Thierig announced a 20 percent increase in Model Y production starting in July, following a record Q1 output of more than 61,000 vehicles. To support the ramp-up, Tesla plans to hire approximately 1,000 new employees beginning in May and convert 500 temporary workers to permanent positions.

The move is expected to lift weekly production significantly, addressing rebounding demand in Europe after a challenging 2025.

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The expansion builds on earlier progress. In 2025, Tesla secured partial approvals to add roughly 2 million square feet of factory space, raising potential annual vehicle capacity from around 500,000 toward 800,000 units, with longer-term ambitions approaching one million vehicles per year. Logistical improvements, new infrastructure, and battery-related facilities are already underway on company-owned land.

Battery production is the latest major focus. On May 12, Thierig revealed an additional $250 million investment in the on-site cell factory. This more than doubles the planned 4680 battery cell capacity to 18 gigawatt-hours annually—up from the 8 GWh target set in December 2025—while creating over 1,500 new battery-related jobs.

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Total cell investments at the site now exceed previous figures, bringing the factory closer to full vertical integration: cells, packs, and vehicles produced under one roof. Tesla describes this as unique in Europe and a step toward stronger supply chain resilience.

The plans come amid regulatory and community hurdles. Earlier expansion proposals faced protests over environmental concerns and water usage, leading to phased approvals beginning in 2024. Tesla has navigated these by emphasizing sustainable practices and economic benefits, including thousands of local jobs in Brandenburg.

With nearly 12,000 employees already on site and production steadily climbing, Gigafactory Berlin is poised for growth. The combined vehicle and battery expansions position the plant as a key hub for Tesla’s European ambitions, potentially making it one of the continent’s largest manufacturing complexes if local support continues.

As EV demand recovers, these investments underscore Tesla’s commitment to scaling efficiently in Germany while addressing regional supply chain needs.

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Honda gives up on all-EV future: ‘Not realistic’

Mibe believes the demand for its gas vehicles is certainly strong enough and has changed “beyond expectations.” As many drivers went for EVs a few years back, hybrids are becoming more popular for consumers as they offer the best of both worlds.

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honda logo with red paint
Ivan Radic, CC BY 2.0 , via Wikimedia Commons

Honda has given up on a previous plan to completely changeover to EVs by 2040, a new report states. The company’s CEO, Toshihiro Mibe, said that the idea is “not realistic.”

Mibe believes the demand for its gas vehicles is certainly strong enough and has changed “beyond expectations.” As many drivers went for EVs a few years back, hybrids are becoming more popular for consumers as they offer the best of both worlds.

Mibe said (via Motor1):

“Because of the uncertainty in the business environment and also the customer demand, is changing beyond our expectation and, therefore, we have judged that it’ll be difficult to achieve. That ratio [100-percent electric in 2040] is not realistic as of now. We have withdrawn this target.”

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Instead of going all-electric, Honda still wants to oblige by its hopes to be net carbon neutral by 2050. It will do this by focusing on those popular hybrid powertrains, planning to launch 15 of them by March 2030.

Honda will invest 4.4 trillion yen, or almost $28 billion, to build hybrid powertrains built around four and six-cylinder gas engines.

There are so many companies abandoning their all-electric ambitions or even slowing their roll on building them so quickly. Ford, General Motors, Mercedes, and Nissan have all retreated from aggressive EV targets by either cancelling, delaying, or pausing the development of electric models.

Hyundai’s 2030 targets rely on mixed offerings of electric, hybrid & hydrogen vehicles

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Early-decade pledges from multiple brands proved overly ambitious as infrastructure lags, battery costs remain high in some markets, and many buyers prefer hybrids for their convenience and range. Toyota has long championed hybrids, while others have quietly extended internal-combustion timelines.

For Honda—historically known for reliable gasoline engines—this shift leverages its core strengths while buying time to refine electric technology. Whether the hybrid-heavy strategy will protect market share in an increasingly competitive landscape remains to be seen, but one thing is clear: the gas engine is far from dead at Honda, unfortunately.

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Delta Airlines rejects Starlink, and the reason will probably shock you

In a pointed exchange on X, Elon Musk defended SpaceX’s uncompromising approach to Starlink’s in-flight internet service, explaining why Delta Air Lines walked away from a deal.

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Delta Airlines Airbus photographed April 2024 Delta-owned. No expiration date, unrestricted use.

SpaceX frontman Elon Musk explained on Wednesday why commercial airline Delta got cold feet over offering Starlink for stable internet on its flights — and the reason will probably shock you.

In a pointed exchange on X, Elon Musk defended SpaceX’s uncompromising approach to Starlink’s in-flight internet service, explaining why Delta Air Lines walked away from a deal.

Delta rejected Starlink because it insisted on routing all connectivity through its branded “Delta Sync” portal rather than allowing a simple Starlink experience.

Instead, the airline partnered with Amazon’s Project Kuiper—rebranded as Amazon Leo—for high-speed Wi-Fi on up to 500 aircraft, with rollout targeted for 2028. At the time of the announcement, Kuiper had roughly 300 satellites in orbit, while Starlink operated more than 10,400.

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The use of the “Delta Sync” portal would not work for SpaceX, as Musk went on to say that:

“SpaceX requires that there be no annoying ‘portal’ to use Starlink. Starlink WiFi must just work effortlessly every time, as though you were at home. Delta wanted to make it painful, difficult and expensive for their customers. Hard to see how that is a winning strategy.”

Musk doubled down in a follow-up post:

“Yes, SpaceX deliberately accepted lower revenue deals with airlines in exchange for making Starlink super easy to use and available to all passengers.”

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SpaceX has structured its airline agreements to prioritize zero-friction access—no captive portals, no SkyMiles logins, no paywalls or ads blocking basic connectivity.

While this means forgoing higher-margin deals that would let carriers monetize the service more aggressively, it ensures Starlink feels like home broadband at 35,000 feet. Passengers on partner airlines such as United, Qatar Airways, and Air France have already praised the service for enabling seamless video calls, streaming, and work mid-flight without interruptions.

Delta’s choice reflects a different philosophy. By keeping Wi-Fi behind its Delta Sync ecosystem, the airline aims to drive loyalty program engagement and control the digital passenger journey. Yet, critics argue this short-term control comes at the expense of immediate competitiveness.

Airlines already installing Starlink are pulling ahead in customer satisfaction surveys, while Delta passengers face years of reliance on slower, legacy systems until Leo launches.

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SpaceX’s decision to trade revenue for simplicity will pay off in the longer term, as Starlink is already positioning itself as the default high-speed option for carriers that value passenger satisfaction over incremental fees.

Musk’s focus on creating not only a great service but also a reasonable user experience highlights SpaceX’s prowess with Starlink as it continues to expand across new partners and regions.

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