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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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Google just picked SpaceX for its first step into orbital AI

Google will launch its first Project Suncatcher AI satellite on SpaceX’s Transporter-18 rideshare next week.

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Google is about to put its own AI chips into orbit for the first time, and it is paying SpaceX to get them there.

The company said Thursday that the first in-orbit test of Project Suncatcher, its research effort to find out whether space can host large-scale AI computing, will fly next week on SpaceX’s Transporter-18 rideshare mission.

The satellite, called MVP, is about the size of a refrigerator and carries four of Google’s Tensor Processing Units, the same chips Google runs in its ground data centers. Google originally planned to launch two custom satellites in 2027, but chose to move faster by integrating its chips into a satellite.

MVP’s solar panels supply about one kilowatt of power, and Google will run Gemini models on the TPUs only in bursts of roughly 15 minutes before the chips shut down so the radiators can shed heat. In a blog post, Google said its Trillium TPUs survived vibration testing that mimicked sustained launch loads of up to 10g, with individual components seeing 50 to 100g, and handled a radiation dose greater than a five year mission would deliver.

SpaceX and Google mull massive partnership on Musk’s orbital data dream: report

Next week’s flight, slated for October 1, follows a relationship that became public in May, when Teslarati reported that Google was in talks with SpaceX for a launch deal tied to orbital data centers. Google also holds a stake of roughly 6% in SpaceX.

The two companies are chasing the same idea from very different starting points. SpaceX’s own orbital compute program is built around the AI1 satellite, a roughly 70 meter structure derived from Starlink V3 hardware that is designed for 150 kW of peak compute, about 150 times the power MVP will draw. Elon Musk has brushed off concerns about crowding orbit with those satellites, and SpaceX is building its Gigasat factory in Bastrop, Texas, to produce them, targeting an annualized rate of about 1 GW of space compute by the end of 2027.

Musk also posted on X on Thursday that “the amount of compute in space will obviously round up to 100% of all compute.”

Google has been more cautious in public. Its research estimates that launch prices need to fall below about $200 per kilogram before an orbital data center can compete with a ground facility on energy cost, a threshold the company believes could be reached around the mid 2030s. The Suncatcher team has said it expects the effort to remain a project rather than a product for years, which leaves the first real test of its hardware riding on a rocket from the company with the most aggressive timeline in the field.

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Tesla Cybercab gets initial tie-in to localized, in-house cathode plant

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Credit: Tesla

Tesla has taken another concrete step toward owning its battery supply chain, and it’s doing so with what is perhaps the most important vehicle in its short-but-storied history.

On September 23, Tesla announced that it has officially built the first Cybercab with cathode material produced in-house at the company’s first cathode plant in the U.S., and the first in the U.S. overall.

Active cathode material is the most expensive piece of a lithium-ion battery cell, and it often accounts for more than a third of cell cost. For years, the industry sourced a majority of it from Asia, but Tesla’s decision to make it in the United States bodes well for the Cybercab project. This is the latest chapter in Tesla’s vertical integration strategy, which began in public at Battery Day in 2020.

At the Battery Day Event, Elon Musk said the company would build a North American cathode plant and overhaul the process to cut costs and waste, while also making some of the most powerful and long-lasting cells in the industry.

The Austin facility took years to appear. Tesla filed permits for “Project Cathode” in 2022 on land near Giga Texas. By mid-2022, the building frame was up and Tesla later invested hundreds of millions of dollars as part of a larger expansion of the Giga Texas plant. The company stated it was operating the first large-scale cathode production facility in North America to supplement 4680 cell production.

One month later, that material reached a finished Cybercab.

The timing of this breakthrough is monumental for the Cybercab program. As Tesla officially launched the first Cybercab rides to the public earlier this month, production of the ride-hailing-geared vehicle is moving forward on the planned S-curve that CEO Elon Musk told everyone to expect.

Nevertheless, packs of Cybercab units have been spotted throughout the United States, in an effort to potentially activate the fleet as soon as the company gains regulatory approval in various geographic areas.

On top of that, Tesla owning the cathode step and pairing it with its own in-house lithium from the Gulf Coast refinery shortens the supply chain that once stretched thousands of miles and subjects every pack to fewer external price shocks and geopolitical risks.

Tesla is not yet independent of all of its foreign suppliers, as some precursor metals come from mines and chemical plants. But the first in-house cathode Cybercab shows the company is closing the most expensive and most concentrated gap in its battery production efforts. For a vehicle like Cybercab to operate at a high utilization within the Robotaxi network, that control over cost is so crucial.

It is arguably as important as the software that drives it.

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Tesla leaks Semi customers ahead of handover event

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Credit: Tesla

Tesla is set to inaugurate its dedicated Semi factory in Sparks, Nevada, this evening, but drone footage has already started to show who is expected on the handover stage.

Zanegler, a drone operator who regularly documents Tesla Semi operations in Nevada, filmed a row of new-generation Semi units parked outside of the plant with customer branding applied. The liveries visible in the video include companies like PepsiCo, U.S. Foods, Einride, DHL, WattEV, and others that have committed to utilizing Tesla’s Class 8 electric truck in their fleets.

Several of those company names already sit within Tesla’s public ordering book, including PepsiCo, which has been the program’s primary anchor customer since the first Semi deliveries in December 2022. PepsiCo now runs dozens of Tesla Semi units in daily service, with drivers completing regional routes.

Einride placed a 500-unit order in August, which was, at the time, the largest single Semi commitment. First deployments of their Semi units are planned for this month and will eventually span across California, Texas, New Jersey, Illinois, and Georgia. Meanwhile, IMC Logistics announced a 50-truck California order this week.

Tesla Semi lands the biggest electric truck deal in U.S. history

Other names, like LTS, OK Produce, and HMD, have not been widely confirmed as firm buyers, but their presence on the lot is perhaps the clearest signal that Tesla intends to expand on that list this evening at the event.

Tesla first unveiled the Semi back in 2017 with a 2019 production target.

Limited pilot builds reached PepsiCo in late 2022, and high-volume production began at the new 1.7-million-square-foot plant that sits logically positioned next to Tesla’s Gigafactory Nevada. Tesla Semi program director Dan Priestley has said that Tesla expects to build “many thousands” of Semi units this year, but as with every Tesla release, there have been set expectations of an S-curve ramp.

Outside estimates still put 2026 deliveries in the 5,000-to-15,000 range, but it will ultimately depend on Tesla’s readiness to put those units out, as well as how smoothly production is moving internally.

Tesla’s Semi Rollout event is set to start tonight at the Sparks factory, and it will be livestreamed on X starting at 6 p.m. PDT / 9 p.m. ET.

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