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Crew Dragon is lifted off the deck of SpaceX recovery vessel GO Searcher after safely arriving at Port Canaveral, March 10th. (NASA) Crew Dragon is lifted off the deck of SpaceX recovery vessel GO Searcher after safely arriving at Port Canaveral, March 10th. (NASA)

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SpaceX’s Crew Dragon suffers catastrophic explosion during static fire test

Crew Dragon C201 is lifted off the deck of a SpaceX recovery vessel on March 10th. C201 was destroyed in an explosion on April 20th. (NASA)

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Six weeks after the spacecraft completed its orbital launch debut, SpaceX’s first flight-proven Crew Dragon capsule suffered a catastrophic explosion seconds before a planned SuperDraco test fire.

In the last nine years, SpaceX has successfully built, tested, launched, and recovered Cargo and Crew Dragons 18 times, including five instances of Cargo Dragon capsule reuse, all with minor or no issues. The April 20th event is the first time in the known history of SpaceX’s orbital spacecraft program that a vehicle – in this case, the first completed and flight-proven Crew Dragon capsule – has suffered a total failure. Regardless of the accident investigation’s ultimate conclusions, the road ahead of Crew Dragon’s first crewed test flight has become far more arduous.

According to information acquired by NASASpaceflight.com, SpaceX was in the middle of a series of static fire tests meant to verify that the flight-proven capsule was in good working order after Crew Dragon’s inaugural mission to orbit. The spacecraft was to be tested near SpaceX’s Cape Canaveral Landing Zone facilities, where the company has a small but dedicated space for Dragon tests. Crew Dragon C201’s testing began earlier on Saturday, successfully firing up its smaller Draco maneuvering thrusters. This transitioned into a planned SuperDraco ignition, what would have been the first such integrated test fire for capsule C201.

SpaceX planned to rapidly reuse Crew Dragon C201 for an upcoming in-flight abort (IFA) test, in which the spacecraft would be required to successfully escape from Falcon 9 at the point of peak aerodynamic stress (Max Q). Based on a leaked video of the failure, one or several faults in Crew Dragon’s design and/or build led to a near-instantaneous explosion that destroyed the spacecraft. Sound in the background seems to indicate that the explosion occurred several seconds before the planned SuperDraco ignition, a major concern given their pressure-fed design.

https://twitter.com/Astronut099/status/1119825093742530560

As pressure-fed rocket engines specifically designed to be the basis of a launch escape system, Crew Dragon and its SuperDraco thrusters are meant to be ready to ignite at a millisecond’s notice once they are armed in a flight-ready configuration. It’s safe to say that ten seconds away from a specifically planned ignition is one of those moments, although there is a limited chance that SpaceX’s static fire procedures intentionally diverge from an abort-triggered ignition. Regardless, the fact that Crew Dragon was destroyed before the ignition of its SuperDracos is not an encouraging sign.

Instead of a problem with its high-performance abort thrusters, it can be tentatively concluded that Crew Dragon’s explosion originated in its fuel tanks or propellant plumbing. Such an immediate and energetic explosion points more towards a total failure of propellant lines or valves (or their avionics), while another – and potentially far more concerning – cause could be one of Crew Dragon’s pressure vessels. In a space as enclosed as a Dragon capsule, the rupture of a pressure vessel could trigger a chain reaction of pressure vessel failures, freeing both oxidizer (NTO) and fuel (MMH). Known as hypergolic propellant, NTO and MMH ignite immediately (and violently so) when mixed.

It’s quite possible that the accident investigation to follow will be SpaceX’s most difficult and trying yet. Regardless of the specific cause, the footage of Crew Dragon C201’s demise does not support any positive conclusions about the fate of astronauts or passengers, had they been aboard during the violent explosion. Seemingly triggered in some way by the very system meant to safely extricate Crew Dragon and its astronauts from a failing Falcon 9 rocket, major work will need to be done to prove to NASA that the spacecraft is safe. Sadly, Boeing’s Starliner spacecraft – funded in parallel with Crew Dragon under NASA’s Commercial Crew Program – suffered a far less severe but no less significant failure during a static fire test of its own abort thrusters. Boeing was forced to remove the impacted hardware from its flight plans to extensively clean, repair, and rework the service module.

https://twitter.com/JimBridenstine/status/1119754804258062337

NASA is now faced with the fact that both of the spacecraft it supported with CCP have exhibited major failures related to their launch escape systems. Crew Dragon’s catastrophic explosion comes as a particularly extreme surprise given how extensively SpaceX has already tested the SuperDraco engines and plumbing, as well as the successful completion of the spacecraft’s launch debut. In the process of DM-1 launch preparations, Crew Dragon likely spent a minimum of 80 minutes with its SuperDraco thrusters and propellant systems primed and ready to abort at any second, apparently without a single mildly-concerning issue.

Godspeed to SpaceX and NASA as they enter into this challenging and unplanned failure investigation.

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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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SpaceX’s Gwynne Shotwell just made a quiet gesture toward Tesla

SpaceX president Gwynne Shotwell quietly followed Tesla on X, and merger watchers noticed right away.

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SpaceX President and COO Gwynne Shotwell has started following Tesla’s official account on X, a small change that landed in the middle of a very loud merger conversation. Whole Mars Catalog joked about it on Sunday.

A follow is not an announcement, and neither company has said anything about a deal. What gives the moment weight is the timing. Barclays analyst Dan Levy has told clients that an agreement could come before Tesla’s annual meeting, which must be held by December 6, with SpaceX as the buyer in an all stock deal, as we reported after the Roadster unveiling. Wedbush’s Dan Ives has stuck with a 2027 timeline.

Shotwell is the executive most worth watching if the two companies do move closer. When Musk was asked at the All In Summit why Tesla and SpaceX remain separate, Shotwell sat next to him and said SpaceX personnel had already moved into xAI to fill leadership and engineering gaps. The businesses were integrating “faster than I thought,” she said, though “not fully integrated yet.” Her responsibilities have also grown since SpaceX absorbed xAI, and she now oversees operations that include Grok and the company’s AI compute buildout.

The financial links are already there. Tesla’s $2 billion xAI investment turned into a stake of less than one percent in SpaceX, the two share the Terafab chip project in Austin, and Musk exercised his 2018 Tesla options a week after SpaceX began trading, a sequence analysts flagged as giving SpaceX public shares to use in a deal. Musk holds about 20 percent of Tesla and controls 85.1 percent of SpaceX’s voting power, according to our earlier breakdown.

The next test is close at hand. SpaceX reports its second earnings as a public company on Tuesday after the close, and Tesla follows on Wednesday. Musk told analysts in July that “we can’t talk about combining companies and that kind of thing on an earnings call,” so a direct answer is unlikely from either stage. Tesla shareholders can still submit and vote on questions through the Say portal until 4 p.m. EDT on Monday, and the merger is a recurring theme in the queue.

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Elon Musk

Tesla Roadster owners to get “Flying Stunt Mode” and looping track access

Musk says Roadster owners can command the unveiling stunts autonomously, with a Texas looping track.

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Elon Musk says owners of the new Tesla Roadster will be able to ask the car to perform the stunts Tesla showed at its unveiling, with the car doing the driving itself. Musk made the comment Saturday in a reply on X to tech blogger Robert Scoble, and he added a promise of a looping track at Tesla’s Texas headquarters.

Scoble had argued that the person in the Roadster is not really driving it. In his description, the driver operates a computer that tells another computer what to do, with steering, braking and acceleration all handled by wire. Musk answered, “True. You will be able to ask the Roadster to perform any of the tricks shown autonomously, as it will be sentient. Also, we will have a wild looping track (crazier even than Hot Wheels) at our Texas HQ where you can test out your Roadster.”

At the October 15 event outside Waco, the car drove up a curved ramp until it was upside down, flew off on cold gas thrusters, flipped and landed. It also hovered over a Cybercab, Cybertruck, Semi, Model Y and Model 3 while moving. As we noted in our breakdown of the three Roadster configurations, Musk said at the event that the car “literally is just going to puff itself up” to perform the maneuvers whenever an owner wants. Saturday’s reply adds that the car would run them on its own.

Tesla has described some of the hardware that would make that possible. The Roadster uses steer by wire with a yoke, and its cold gas thrusters rely on electric actuators for small adjustments in flight. A fan system under the car creates suction, which Tesla says is strong enough to hold it upside down, a setup we covered in our look at the Roadster’s fan system and thrusters.

Musk did not say when an autonomous stunt feature might arrive, how it would work, or what he means by sentient. He also gave no size, location or opening date for the Texas track. Production is planned for Giga Texas in 2027 or 2028, and Tesla says the car is not approved for public road use. The Rocket version, the one built to fly, is invite only.

The comment follows a week of Musk teasing the event, including his claim that the demo would be a banger, which we covered before the stream. Tesla reports third quarter earnings on October 21, and shareholders can submit and vote on questions through the Say portal until 4 p.m. EDT on October 20, according to our earnings Q&A preview. A question about autonomous Roadster stunts and the Texas track would be a quick way to get specifics from management.

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Elon Musk

How to use Grok Bot to block spam calls and texts

Musk told users to ask Grok Bot to scrub their phone numbers from spam lists.

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Elon Musk has a new use case for Grok Bot, and it is the spam call. On Thursday he replied to an X user named Arash with a short instruction: “Ask your @Grok @Bot to remove your phone number from spam call & text lists!” Arash had said he got tired of the calls, had an AI bot find his number on listing sites and file removal requests, and packaged the process as a free skill for others.

The skill is called Spam-Call Scrubber, which is described to find a phone number on people search sites and data brokers, submits the opt outs, completes the confirmation emails those sites send back, and rechecks on a schedule the user picks. Using it requires the Grok Bot app. The pitch is time saved, since most broker opt outs sit behind separate forms on separate sites.



Musk said Grok Bot now gives each bot its own email address, and that it can detect scam emails. On Thursday he also said SpaceX would make users whole if the bot botches a purchase or leaks a card, then told users to shop away from Amazon after the retailer blocked the agent, as Teslarati reported. The terms of service we reviewed at the time put responsibility for what an agent does on the user.

For Tesla owners, Grok Bot is not just a phone app. Tesla brought Grok Bot into its vehicles on September 22, and we argued earlier this week that the Cybercab’s real advantage may be the errands it runs during a ride. Every Cybercab and the rest of the Model Y Robotaxi fleet has it enabled. The more routine tasks like this one become, the more a rider has reason to hand over something personal in the back seat.

The new Spam-Call Scrubber skill can be downloaded for free and works on sites that honor removal requests, while noting that listings can reappear, and illegal robocallers do not check any registry. Whether Spam-Call Scrubber cuts anyone’s call volume is something the first wave of users will find out, and Musk’s endorsement guarantees that wave is coming.

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