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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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8 years ago

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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.

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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.

“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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Tom Cross – Twitter

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Pauline Acalin – Twitter

Eric Ralph – Twitter

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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

This tiny Tesla Cybertruck adjustment has big advantages

Published

1 hour ago

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September 9, 2026

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Credit: Wes Morrill | X

Yesterday, we reported on Tesla Cybertruck getting some major adjustments from a manufacturing standpoint in an effort to make the all-electric pickup more cost-effective, more reliable, more serviceable, and more easily produced.

Tesla Cybertruck engineer reveals new changes in ‘constantly evolving’ pickup

One of those changes was the addition of a self-reinforcing polypropylene aero shield that sits underneath the truck. Previously, Tesla utilized aluminum for this, but the self-reinforcing polypropylene was more durable while also being cheaper and lighter.

Tesla has revealed another small change it made to the Cybertruck, and it has to do with the side repeater cameras.

Tesla does not wait for a new model year to improve its vehicles. On September 8, Cybertruck lead engineer Wes Morrill posted side-by-side photos of an updated side repeater camera housing now rolling off the line at Gigafactory Texas.

The triangular camera pod mounted on the front fender looks almost identical at first glance. A closer look reveals a revised contour that uses the air already flowing around the truck to keep the lens clearer in rain and road spray.

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The side repeater cameras sit in an exposed position on the Cybertruck’s angular stainless-steel body.

In wet weather, they readily collect water droplets that can degrade the image Autopilot and Full Self-Driving use for lane changes and blind-spot monitoring. Early production trucks sometimes left owners wiping lenses by hand or accepting temporary restrictions on driver-assistance features.

Tesla has added washers to cameras on certain other models and on Cybercab prototypes, but those active systems add cost, complexity, and extra potential leak points.

The new housing solves the problem with passive geometry. Subtle changes in the surround create localized airflow disturbances as the vehicle moves. Those eddies physically push water droplets away from the optical surface. Morrill called the result “pure vision improvement” achieved at “no cost penalty.” Once the production mold is updated, every subsequent part costs the same as the original.

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The advantages compound quickly. Clearer cameras in rain improve the reliability of driver-assistance features precisely when they are needed most. The design consumes no extra energy and introduces no new failure modes.

New Cybertrucks built after the tooling changeover receive the updated part automatically. Some owners of trucks delivered as late as June 2026 have already confirmed they received the revised housing. Retrofit questions have appeared in replies, and the cameras appear electrically compatible, though Tesla has not announced an official service program.

A few millimeters of reshaped housing will not make headlines the way a new battery pack does, but these changes are incremental and increase the Cybertruck’s effectiveness as a vehicle over time.

This improvement illustrates how Tesla continues to refine the Cybertruck after volume production began. Better wet-weather vision, zero added cost, and no extra hardware add up to a meaningful gain in everyday usability and safety.

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News

Tesla is rolling out a new FSD version with a massive safety addition

Published

2 hours ago

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September 9, 2026

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Credit: Tesla

Tesla is rolling out a new version of its Full Self-Driving suite to some owners that comes with the massive addition of a safety feature.

Tesla is rolling out Automatic Collision Evasion with the 2026.27.6 Software Update, which started rolling out to some vehicles last night. We received the update, along with Full Self-Driving v14.3.9, as well as v14.2 Lite, which has identical release notes as the previous version and seems to have some refinements and improvements in behavior and performance.

However, most of the attention has fallen on the Automatic Collision Evasion feature, which we covered in an article last week.

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The function will activate Full Self-Driving to “try to keep your vehicle safe and then continue driving. It can engage in the following situations while you are driving manually:

  • Scenario 1: A frontal collision is imminent and braking alone may not avoid it.
  • Scenario 2: Your vehicle detects that you are not sufficiently attentive to the road (for example, reaching toward the back seat), or that Full Self-Driving (Supervised) may have been unintentionally disengaged.”

Essentially, FSD will take over when the vehicle determines you are not paying sufficient attention or are heading toward a potential collision. The addition of this feature is incredibly useful as distracted driving is a major issue in today’s world.

Along with the new safety feature is Tesla FSD v14.3.9, which has no additional release notes compared to the previous version, but in my first drives, my first impression is that operation is great, and parking is still sort of a pain point.

Additionally, Tesla v14.2. Lite has arrived. A great review of that is available here:

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The addition of an Automatic Collision Evasion feature is similar to that of other collision avoidance systems that are used by companies like Hyundai, Kia, and Genesis. These programs typically utilize radar and camera sensors to apply emergency brakes autonomously, though evasive steering in a manual driving mode is pioneered primarily by Tesla’s newest addition.

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Elon Musk

Tesla primes Cybercabs for 4K streaming and high bandwidth gaming with Starlink integration

Tesla is now shipping Cybercabs from Giga Texas with Starlink hardware built in as standard.

Published

10 hours ago

on

September 8, 2026

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tesla cybercab with no manual controls showing a movie with two employees inside

Tesla’s Cybercabs are now leaving Gigafactory Texas with Starlink hardware on the rear hatch in significant numbers, according to drone footage captured Tuesday by longtime Austin drone observer Joe Tegtmeyer. Production at the factory ramped back up after the Labor Day weekend, and his flyover of the outbound lot showed rows of gold Cybercabs alongside Model Y Long Wheelbase units, many carrying the satellite module for the first time as standard equipment rather than a one off retrofit.

Tesla first showed Starlink built into an actual Cybercab on August 10, when the Robotaxi account posted images of a single gold unit with the antenna integrated into the roofline above the taillights and called it the first Cybercab with Starlink integration. That followed a July reveal where Tesla and Starlink jointly posted a cutaway diagram of the antenna placement without a working vehicle to back it up. Ashok Elluswamy, Tesla’s VP of AI software, said at the time that the connection isn’t required for the car to drive itself. It exists mainly for navigation, customer service and keeping tabs on the fleet.

Musk has made a different case in public. During Tesla’s Q2 earnings call, he said the company can’t afford robotaxis stranded in what he called “Bermuda Triangles of lack of cellular connectivity,” and he separately claimed on X that Starlink will eventually reach every Tesla built, calling it the only way to deliver high bandwidth to billions of vehicles. He has also pitched the antenna as an entertainment upgrade, telling riders they would be able to stream 4K video or play games during a trip.

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The rollout has moved fast since. Robotaxi service opened to the public in Austin on September 3, and Cybercabs had already been spotted with Starlink hardware in Houston and near Miami International Airport in the weeks before Tuesday’s factory footage showed the module shipping at volume rather than on scattered test units. Whether the satellite link earns its keep is still an open question. Tesla’s unsupervised service currently runs in dense metro geofences in Texas and Florida, markets where cellular coverage is already strong, which is not where the rural dead zones Musk describes tend to show up.

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