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SpaceX’s next Crew Dragon astronaut mission settles on Halloween launch

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After initially moving forward 24 hours from October 31st to October 30th, SpaceX’s next Crew Dragon astronaut mission has slipped back to its initial Halloween launch date.

Again scheduled to lift off around 2:21 am EDT (UTC-4) on Halloween morning, SpaceX’s Falcon 9 rocket and Crew Dragon spacecraft are on track to support their third operational NASA astronaut launch since November 2020. Known as Crew-3, the mission will carry NASA astronauts Thomas Marshburn, Raja Chari, Kayla Barron, and ESA (European Space Agency) astronaut Matthias Maurer to the International Space Station (ISS). A few weeks later, Crew-3 will take over command of the US ISS segment, allowing Crew Dragon Crew-2 astronauts Shane Kimbrough, Megan McArthur, Akihiko Hoshide, and Thomas Pesquet to return to Earth after some six and a half months in orbit.

Unlike Crew-2, which became the first astronaut launch in history to use a flight-proven orbital space capsule in April 2021, Crew-3 astronauts will head to the ISS inside a new capsule. Likely to be Dragon 2 capsule #10 (C210), SpaceX says it will be the first of at least two new Crew Dragons scheduled to join the company’s fleet of reusable crew capsules between now and mid-2022. Each Dragon 2 capsule (Crew and Cargo variants) is designed and rated to complete at least five orbital spaceflights before retirement and there’s a good chance that that five-flight limit can be expanded if needed.

Crew Dragon C210 will join four other operational Dragon 2 spacecraft – two Crew, two Cargo. (NASA/Mike Hopkins/ESA/Thomas Pesquet)

New Dragon aside, Crew-3 will still be the second time professional astronauts launch on a flight-proven liquid rocket booster – SpaceX’s Falcon 9. Between Crew-2 and Crew-3, SpaceX also launched four private, rookie astronauts – a world first – on a flight-proven Dragon and Falcon 9 booster, further strengthening the pair’s pedigree as the first privately-developed, reusable, human-rated rocket and spacecraft. Crew-3 will be Falcon 9 booster B1067’s second Dragon launch and second launch overall after a successful Cargo Dragon launch debut in June 2021.

Falcon 9 B1067 is pictured during its first launch and after its first landing. (Richard Angle)

When the Commercial Crew Program culminated in NASA awarding SpaceX $2.6B to develop Crew Dragon and Boeing $4.2B to develop Starliner, the goal was always to field two redundant crew transfer vehicles and then alternate launches of those vehicles every six or so months. However, despite charging NASA almost two-thirds more than SpaceX to provide the exact same service, Boeing’s Starliner program has run into numerous hardware and software issues over the last two years, causing major delays.

As a result, more than 31 months after a SpaceX Crew Dragon aced its first uncrewed test flight to and from the space station and almost 18 months after Dragon launched its first two astronauts, Boeing’s Starliner has yet to complete a successful orbital test flight and yet to launch a single astronaut. Recently, Boeing’s second uncrewed test flight – required after Starliner suffered near-catastrophic software failures on its first attempt – has been delayed by chronic valve issues from July or August 2021 to May 2022. NASA has also begun shuffling astronauts originally scheduled to launch on Starliner’s Crew-1 equivalent mission to Crew Dragon’s August 2022 Crew-5 mission.

Boeing's Starliner and SpaceX's Crew Dragon spacecraft stand vertical at their respective launch pads in December 2019 and January 2020. Crew Dragon has now performed two successful full-up launches to Starliner's lone partial failure. (Richard Angle)
Starliner and Atlas V; Crew Dragon and Falcon 9. (Richard Angle)

Starliner’s first crewed flight test (CFT) is entirely dependent upon the near-flawless success of OFT-2 – far from guaranteed. Per Boeing’s senior Starliner program manager, the current best-case scenario would see the company launch CFT six months after OFT-2 – no earlier than November 2022 if OFT-2 flies next May. In other words, based on the program’s history of chronic delays, it’s more likely than not that Starliner won’t fly crew until early 2023. Given Crew-5’s August 2022 launch target, Boeing would have to ace its crewed flight test, pass extensive NASA post-flight reviews, and achieve NASA certification in just a month or two for SpaceX and Crew Dragon to not end up flying Crew-6 in February or March 2023.

Put simply, Boeing has gotten itself into a situation where it would take a minor miracle for Starliner to complete a single operational launch before SpaceX launches all six NASA Crew Dragon missions currently on contract – and back to back, no less. Crew-3 will mark the halfway point to a milestone that would have been unfathomable just a few years ago.

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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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New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

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

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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