News
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.
News
Elon Musk shuts down Tesla ‘AMG’ division speculation: ‘Focus is autonomy’
“I think it’s best to leave that to the custom shops. Tesla’s focus is autonomous cars, building futuristic autonomous cars. We want the future to look like the future.”
Tesla CEO Elon Musk was asked by Joe Rogan late last week whether the company would ever consider establishing an “AMG division” like Mercedes-Benz has established for powerful, race-inspired vehicles.
However, Musk turned down any talk of that, highlighting that the company is laser-focused on autonomous vehicles, seemingly hinting that any distraction from autonomy would be a detriment to the future.
Rogan drives a Tesla Model S himself, but it is not your run-of-the-mill all-electric sedan. Already outfitted with the Plaid powertrain that Tesla developed, Rogan took his vehicle to Unplugged Performance for a true performance outfitting.
The vehicle is completely overhauled with performance parts and seats. Known as the Model S-APEX, Rogan took delivery of it from Unplugged in January.
Rogan asked Musk on Friday during his most recent appearance on the Joe Rogan Experience podcast whether Tesla would ever establish an “AMG division” that would focus on catering Teslas to performance-based standards.
Musk said:
“I think it’s best to leave that to the custom shops. Tesla’s focus is autonomous cars, building futuristic autonomous cars. We want the future to look like the future.”
🚨 Elon Musk was asked by Joe Rogan if he would ever create an “AMG division” where customization and performance options are available.
Musk said:
“I think it’s best to leave that to the custom shops. Tesla’s focus is autonomous cars, building futuristic autonomous cars. We… pic.twitter.com/k7qy7UQc60
— TESLARATI (@Teslarati) October 31, 2025
Tesla fans have said for years that the company should consider acquiring Unplugged Performance and its Upfit Tesla division, which recently outfitted the Las Vegas Metropolitan Police Department’s fleet of Cybertruck cruisers.
However, it seems Tesla will keep things separate. Musk is primarily focused on autonomy, which will drive the technology forward and drive shareholder growth. Something like an outfitter for performance would be a cool thing for the owners who have the interest and the money.
It’s not a tremendous revenue driver or anything that would contribute to the financial state of the company. Mercedes-Benz, for example, is more accessible for consumers as it sold over 140,000 units from its AMG brand in 2024.
Tesla Model Y driver starts race in reverse, still wins against AMG SUV
It helps with driving revenue higher by as much as 15 percent compared to similar models that are not AMGs. However, would Tesla see this much of a benefit? Likely not, because the Performance trim already caters to many owners.
Cybertruck
Tesla Cybertruck fleet takes over at SpaceX’s Starbase
Interestingly, the Cybertruck uses the same exterior, a stainless steel alloy, as SpaceX rockets. This synergy between the two companies and their very different products shows a very unified mentality between Musk companies.
Tesla Cybertrucks have taken over at SpaceX’s Starbase facility in Texas, as hundreds of the all-electric pickup trucks were spotted late last week rounding out a massive fleet of vehicles.
The Cybertruck fleet is geared toward replacing gas vehicles that are used at Starbase for everyday operations. The only surprise about this is that it was not done sooner:
Was just visiting. pic.twitter.com/5Q9wPPaeuH
— Derek Li (@derek1ee) October 31, 2025
Deliveries have been going on for a few weeks, as Cybertrucks have made their way across the state of Texas from Austin to Starbase so they could be included in SpaceX’s fleet of vehicles at the facility.
Interestingly, the Cybertruck uses the same exterior, a stainless steel alloy, as SpaceX rockets. This synergy between the two companies and their very different products shows a very unified mentality between Musk companies.
However, there are some other perspectives to consider as SpaceX is utilizing such a massive fleet of Cybertrucks. Some media outlets (unsurprisingly) are seeing this as a move of weakness by both Tesla and SpaceX, as the aerospace company is, in a sense, “bailing out” lagging sales for the all-electric pickup.
It’s no secret that Tesla has struggled with the Cybertruck this year, and deliveries have been underwhelming in the sense that the company was anticipating between 1 million and 2 million orders for the vehicle before it was widely produced.
A lot of things changed with the Cybertruck between its 2019 unveiling and 2023 initial deliveries, most notably, price.
The price of the Cybertruck swelled significantly and priced out many of those who had pre-ordered it. Some have weighed the option of whether this purchase was a way to get rid of sitting inventory.
However, it seems more logical to consider the fact that SpaceX was likely always going to transition to Teslas for its fleet, especially at Starship, at some point.
It doesn’t seem out of the question that one Musk company would utilize another Musk company’s products, especially considering the Cybertruck has been teased as the vehicle that would be present on Mars.
Elon Musk
Elon Musk subtly confirms one of Tesla AI8’s uses, and it’s literally out of this world
Elon Musk appears to have subtly confirmed that Tesla’s upcoming AI8 chip won’t be limited to vehicles or robots alone.
Elon Musk appears to have subtly confirmed that the uses of Tesla’s upcoming AI8 chip won’t be limited to vehicles or humanoid robots alone.
If Musk’s recent responses on X are any indication, it would appear that Tesla’s AI8 will be used by the CEO’s other companies, and its applications would literally extend out of this world.
Tesla’s AI8 could extend beyond vehicles
Musk’s update came on the heels of his recent comments, where he revealed that Tesla was not just working on its AI5 and AI6 chips. The company is also designing AI7 and AI8. This comment caught a lot of attention, with some wondering why Tesla feels the need to design an AI8 chip when AI4 seems on track to be a good fit for autonomous driving.
Amidst these speculations, an X user suggested that Elon Musk’s comment about AI8 being out of this world could actually be quite true in the literal sense, as it could be used as the chip for SpaceX’s orbit data centers. Musk subtly confirmed this, as he responded to the X user’s post with a bullseye emoji.
Musk’s subtle confirmation that AI8 will be used by SpaceX’s in-space data centers presents a pretty interesting future for the electric vehicle maker. Synergy among Elon Musk-led companies is nothing new, but having Tesla produce chips for SpaceX is undoubtedly something that’s never really been done before.
SpaceX’s space-based computing with Starlink V3 satellites
Musk previously stated that SpaceX plans to use its Starlink V3 satellites to develop space-based data centers. In response to an Ars Technica report on autonomous space construction, he wrote on X: “Simply scaling up Starlink V3 satellites, which have high-speed laser links, would work. SpaceX will be doing this.”
The concept, while ambitious, could address growing energy and cooling constraints facing Earth-based data centers amid the AI boom. Space-based clusters could also cut down on land and water usage, though critics have questioned their cost and maintainability.
Musk recently called the orbital data center project “a very big deal,” and given SpaceX’s history of turning improbable ideas into operational systems, it may not be too far-fetched at all, especially since SpaceX’s Starlink V3 platform is capable of up to 1 terabit per second (Tbps) throughput.
Elon Musk shuts down Tesla ‘AMG’ division speculation: ‘Focus is autonomy’
Tesla Cybertruck fleet takes over at SpaceX’s Starbase
Elon Musk subtly confirms one of Tesla AI8’s uses, and it’s literally out of this world
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