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NASA denies SpaceX Crew Dragon propellant leak report, reveals unrelated heat shield defect
In a partial response to a report alleging evidence of several significant anomalies during a recent private astronaut launch that could affect a crew of NASA astronauts launched last month, the space agency has issued a statement denying those claims. However, the same statement simultaneously revealed that SpaceX recently discovered a different problem with a different Crew Dragon spacecraft component during ground testing.
On May 23rd, Space Explored published a report alleging that a SpaceX Crew Dragon spacecraft experienced major issues during Axiom-1, the company’s first all-private astronaut launch to the International Space Station (ISS). According to sourced info and a possible internal SpaceX memo, some of Dragon’s toxic propellant leaked during the 17-day flight, damaged or weakened parts of its heat shield, and “[caused] dangerously excessive wear upon reentry.” In general, the report appeared to be well-sourced and even alleged that NASA’s Engineering and Safety Center (NESC) had opened an investigation. Additionally, when approached for comment, neither NASA nor SpaceX were initially willing to speak on the record, which also meant that neither denied the accusations.
A day later, NASA provided an official statement to Space Explored explicitly denying that there has been any propellant leak, heat shield contamination, or excessive heat shield wear on any of “Dragon’s recent crew reentries.”
NASA also dismissed concerns about the reuse of a previously-flown Cargo Dragon 2 heat shield structure on Crew-4, which launched just two days after Axiom-1’s recovery and is scheduled to spend four to five more months in orbit. It also noted that the reuse of Dragon’s heat shield tiles – the structures that take the brunt of most reentry heating and are immersed in salt water after every mission – is extremely limited and has only been attempted on occasional Cargo Dragon missions.
Simultaneously, NASA revealed that “a new heat shield composite structure intended for flight on Crew-5 did not pass an acceptance test” at SpaceX’s Hawthorne, California Dragon factory. The unrelated test failure was blamed on a manufacturing defect and NASA betrayed no sign of serious concern in its statement, suggesting that the problem may be less serious than it sounds. In response, NASA says SpaceX will simply use a different heat shield composite structure for Crew-5, which is scheduled to launch no earlier than (NET) September 2022.
The data associated with Dragon’s recent crew reentries was normal – the system performed as designed without dispute. There has not been a hypergol leak during the return of a crewed Dragon mission nor any contamination with the heat shield causing excessive wear. SpaceX and NASA perform a full engineering review of the heat shield’s thermal protection system following each return, including prior to the launch of the Crew-4 mission currently at the International Space Station. The heat shield composite structure (structure below the tile) was re-flown per normal planning and refurbishment processes. The thermal protection system on the primary heat shield for Crew-4 was new, as it has been for all human spaceflight missions. SpaceX has only demonstrated reuse of selected PICA (Phenolic-Impregnated Carbon Ablator) tiles, which is a lightweight material designed to withstand high temperatures, as part of the heat shield on cargo flights.
NASA and SpaceX are currently in the process of determining hardware allocation for the agency’s upcoming SpaceX Crew-5 mission, including the Dragon heat shield. SpaceX has a rigorous testing process to put every component and system through its paces to ensure safety and reliability. In early May, a new heat shield composite structure intended for flight on Crew-5 did not pass an acceptance test. The test did its job and found a manufacturing defect. NASA and SpaceX will use another heat shield for the flight that will undergo the same rigorous testing prior to flight.
Crew safety remains the top priority for both NASA and SpaceX and we continue to target September 2022 for launch of Crew-5.
NASA – May 24th, 2022
Some oddities do remain. While NASA’s explicit refutation should be taken as the definitive final word on the matter, it’s still very unusual that NASA and SpaceX refused or were unable to quickly and publicly deny the claims within a few hours of being asked. That could simply be a consequence of NASA and SpaceX’s poor internal and external communication or both parties’ love for withholding information from taxpayers about systems and technologies that those same taxpayers have paid for.
On the opposite hand, after Crew Dragon’s Demo-2 run-in with greater-than-expected heat shield wear in 2020, it’s almost impossible to imagine that NASA and SpaceX would have proceeded with Crew-4’s launch two days after Axiom-1’s recovery without confidently verifying that heat shield erosion was within normal bounds. SpaceX’s upgraded Phenolic-Impregnated Carbon Ablator (PICA-X) Dragon heat shield tiles are reportedly designed to erode [PDF] less than a centimeter of their circa-2017 ~7.5 cm (3 in) thickness after each reentry. Musk has gone even further, stating in 2012 that “[PICA-X] can potentially be used hundreds of times for Earth orbit re-entry with only minor degradation each time.” If true, it would be extremely difficult for even a brisk post-flight inspection of Axiom-1’s Dragon capsule to miss what Space Explored described as “dangerously excessive wear.”
In theory, during recovery, even a minute propellant leak should have also been immediately detected by SpaceX’s recovery team, as the very first part of the hands-on process involves a small team with gas masks and detectors approaching the floating capsule to ensure that it’s safe for others to approach. Crew Dragon’s liquid monomethylhydrazine (MMH) fuel and dinitrogen tetroxide (NTO) oxidizer are highly toxic in small quantities and MMH is a known carcinogen.
All told, news of a potential propellant leak and anomalous heat shield performance appears to have been a false alarm, although – coincidentally or not – a seemingly minor anomaly with an unflown Crew Dragon heat shield structure did occur earlier this month. Despite that anomaly, Crew-4 and Crew-5 are otherwise proceeding nominally and NASA appears to be content with Crew Dragon’s performance during several recent launches and recoveries.
Elon Musk appeared on the Moonshots podcast with Peter Diamandis today to discuss AGI, U.S. vs. China, Tesla, and some other interesting topics, but there was some discussion about the upcoming unveiling of the Roadster, the company’s electric supercar that will arrive several years after it was initially slated for release.
Musk made some pretty amazing claims about the Roadster; we already know it is supposed to be lightning-fast and could even hover, if Tesla gets everything to happen the way it wants to. However, the car has some pretty crazy capabilities, some of which have not even been revealed.
On the podcast, Musk said:
“This is not a…safety is not the main goal. If you buy a Ferrari, safety is not the number one goal. I say, if safety is your number one goal, do not buy the Roadster…We’ll aspire not to kill anyone in this car. It’ll be the best of the last of the human-driven cars. The best of the last.”
🚨 Elon on the Roadster unveiling, scheduled for April 1:
— TESLARATI (@Teslarati) January 6, 2026
Musk makes a good point: people who buy expensive sports cars with ridiculous top speeds and acceleration rates do not buy them to be safe. They hope they are safe in case of an emergency or crash, but safety is not at the forefront of their thoughts, because nobody buys a car thinking they’ll crash it.
The Roadster is truly going to push the limits and capabilities of passenger vehicles; there’s no doubt about that. Tesla plans to show off the new version car for the first time on April 1, and Musk has only hinted at what is possible with it.
Musk said back in November:
“Whether it’s good or bad, it will be unforgettable. My friend Peter Thiel once reflected that the future was supposed to have flying cars, but we don’t have flying cars. I think if Peter wants a flying car, he should be able to buy one…I think it has a shot at being the most memorable product unveiling ever. [It will be unveiled] hopefully before the end of the year. You know, we need to make sure that it works. This is some crazy technology in this car. Let’s just put it this way: if you took all the James Bond cars and combined them, it’s crazier than that.”
Production is set to begin between 12 and 18 months after the unveiling, which would put the car out sometime in 2027. Hopefully, Tesla is able to stay on track with the scheduling of the Roadster; many people have been waiting a long time for it.
News
Tesla launches hiring for Robotaxi program in its twentieth country
Overall, the hiring signals Tesla’s aggressive timeline for global dominance in autonomous mobility.
Tesla has launched a hiring initiative for its Robotaxi program in its twentieth country, as the company posted two new jobs in Thailand this week.
Tesla is hiring in Bangkok and Kowloon for the Vehicle Operator position, which is related to data collection, and is the first in Thailand, but the twentieth country overall, as the company tries to expand into other markets.
🚨 BREAKING: Tesla is hiring additional full-time Vehicle Operators in Bangkok, Thailand.
Previous openings were 6-month, part-time roles. These are equivalent to AI Safety Operator roles in the U.S. pic.twitter.com/R6LzoU1bos— Tesla Yoda (@teslayoda) January 5, 2026
Tesla has had active job postings for Vehicle Operator positions in the United States, India, Israel, Taiwan, Germany, the Czech Republic, Hungary, the UK, Finland, Switzerland, Sweden, the Netherlands, Austria, Spain, Norway, Italy, and Turkey in past listings.
These postings are not all currently available, likely because the roles have been filled.
Thailand is the most recent, and broadens the company’s potential path to expanding its ride-hailing program, which is only active in the United States in Austin, Texas, and the California Bay Area, so far.
These roles typically involve data collection, which assists in improving Autopilot and Full Self-Driving operation. Tesla’s self-driving programs utilize real-world data that is accumulated and stored, observing vehicle and traffic behavior, as well as tendencies that are performed by human drivers to help increase safety and overall performance.
Overall, the hiring signals Tesla’s aggressive timeline for global dominance in autonomous mobility. Although the company has several high-profile rivals and competitors in the field, it has established itself as a main player and a leader in the development of autonomous technology, especially in the U.S., as its FSD suite is refined on almost a weekly basis.
The Full Self-Driving suite is available in seven countries and territories currently, including the U.S., Canada, China, Mexico, Puerto Rico, Australia, and New Zealand. Its biggest goal for expansion is currently the European market, where regulatory hurdles have been the main bottleneck prolonging its launch on the continent.
Tesla has performed months of testing in various European countries, including France and Spain, and does have support in some areas from various regulatory agencies. However, the company is hoping to get through this red tape and offer its suite in Europe for the first time, hopefully this year.
News
Tesla China rolls out Model Y upgrades, launches low-interest financing
These strategies are aimed at improving the ownership experience and keeping vehicle pricing competitive in the world’s largest electric vehicle market.
Tesla has rolled out minor updates to the five-seat Model Y in China, upgrading the vehicle’s center display to a higher-resolution 16-inch 2K screen. The electric vehicle maker also introduced attractive financing options, including 7-year low-interest rates, to offset the new purchase tax on EVs.
These strategies are aimed at improving the ownership experience and keeping vehicle pricing competitive in the world’s largest electric vehicle market.
Five-seat Model Y gets larger, better display
With its recent update, all three variants of the five-seat Model Y now feature an upgraded 16-inch 2K resolution center display, which replaces the vehicle’s previous 15.4-inch 1080p panel. This screen was already used in the six-seat Model Y L, and it offered improved visual clarity. Tesla China has also updated the Model Y’s headliner to black, giving the vehicle a sleeker appearance.
Prices of the five-seat Model Y remain unchanged at RMB 263,500, RMB 288,500, and RMB 313,500 for the respective trims. This update enhances the cabin experience as domestic rivals are already adopting high-resolution screens. As noted in a CNEV Post report, some domestic automakers have begun rolling out vehicles equipped with 3K-resolution displays.
New financing offers
Tesla also launched ultra-long-term financing offers for its locally produced models in China, which include the Model 3 sedan, the five-seat Model Y, and the six-seat Model Y L, through January 31, 2026. The 7-year option features an annualized fee rate as low as 0.5%, which is equivalent to 0.98% interest. This is expected to save customers up to RMB 33,479 ($4,790) compared to standard rates.
A 5-year zero-interest plan is also available, and it has been extended to the Tesla Model Y L for the first time. These incentives help offset China’s new 5% purchase tax on New Energy Vehicles (NEVs) in 2026-2027. Some of Tesla’s rivals in China have announced in recent months that they would be covering the purchase tax owed by buyers early this year.
Elon Musk just said some crazy stuff about the Tesla Roadster
Tesla launches hiring for Robotaxi program in its twentieth country
