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.
Elon Musk
Tesla begins expanding Robotaxi access: here’s how you can ride
You can ride in a Tesla Robotaxi by heading to its website and filling out the interest form. The company is hand-picking some of those who have done this to gain access to the fleet.
Tesla has begun expanding Robotaxi access beyond the initial small group it offered rides to in late June, as it launched the driverless platform in Austin, Texas.
The small group of people enjoying the Robotaxi ride-hailing service is now growing, as several Austin-area residents are receiving invitations to test out the platform for themselves.
The first rides took place on June 22, and despite a very small number of very manageable and expected hiccups, Tesla Robotaxi was widely successful with its launch.
Tesla Robotaxi riders tout ‘smooth’ experience in first reviews of driverless service launch
However, Tesla is expanding the availability of the ride-hailing service to those living in Austin and its surrounding areas, hoping to gather more data and provide access to those who will utilize it on a daily basis.
Many of the people Tesla initially invited, including us, are not local to the Austin area.
There are a handful of people who are, but Tesla was evidently looking for more stable data collection, as many of those early invitees headed back to where they live.
The first handful of invitations in the second round of the Robotaxi platform’s Early Access Program are heading out to Austin locals:
I just got a @robotaxi invite! Super excited to go try the service out! pic.twitter.com/n9mN35KKFU
— Ethan McKanna (@ethanmckanna) July 1, 2025
Tesla likely saw an influx of data during the first week, as many traveled far and wide to say they were among the first to test the Robotaxi platform.
Now that the first week and a half of testing is over, Tesla is expanding invites to others. Many of those who have been chosen to gain access to the Robotaxi app and the ride-hailing service state that they simply filled out the interest form on the Robotaxi page of Tesla’s website.
That’s the easiest way you will also gain access, so be sure to fill out that form if you have any interest in riding in Robotaxi.
Tesla will continue to utilize data accumulated from these rides to enable more progress, and eventually, it will lead to even more people being able to hail rides from the driverless platform.
With more success, Tesla will start to phase out some of the Safety Monitors and Supervisors it is using to ensure things run smoothly. CEO Elon Musk said Tesla could start increasing the number of Robotaxis to monitors within the next couple of months.
A Tesla analyst today said that investors should not lose sight of what is truly important in the grand scheme of being a shareholder, and that any near-term drama between CEO Elon Musk and U.S. President Donald Trump should not outshine the progress made by the company.
Gene Munster of Deepwater Management said that Tesla’s progress in autonomy is a much larger influence and a significantly bigger part of the company’s story than any disagreement between political policies.
Munster appeared on CNBC‘s “Closing Bell” yesterday to reiterate this point:
“One thing that is critical for Tesla investors to remember is that what’s going on with the business, with autonomy, the progress that they’re making, albeit early, is much bigger than any feud that is going to happen week-to-week between the President and Elon. So, I understand the reaction, but ultimately, I think that cooler heads will prevail. If they don’t, autonomy is still coming, one way or the other.”
BREAKING: GENE MUNSTER SAYS — $TSLA AUTONOMY IS “MUCH BIGGER” THAN ANY FEUD 👀
He says robotaxis are coming regardless ! pic.twitter.com/ytpPcwUTFy
— TheSonOfWalkley (@TheSonOfWalkley) July 2, 2025
This is a point that other analysts like Dan Ives of Wedbush and Cathie Wood of ARK Invest also made yesterday.
On two occasions over the past month, Musk and President Trump have gotten involved in a very public disagreement over the “Big Beautiful Bill,” which officially passed through the Senate yesterday and is making its way to the House of Representatives.
Musk is upset with the spending in the bill, while President Trump continues to reiterate that the Tesla CEO is only frustrated with the removal of an “EV mandate,” which does not exist federally, nor is it something Musk has expressed any frustration with.
In fact, Musk has pushed back against keeping federal subsidies for EVs, as long as gas and oil subsidies are also removed.
Nevertheless, Ives and Wood both said yesterday that they believe the political hardship between Musk and President Trump will pass because both realize the world is a better place with them on the same team.
Munster’s perspective is that, even though Musk’s feud with President Trump could apply near-term pressure to the stock, the company’s progress in autonomy is an indication that, in the long term, Tesla is set up to succeed.
Tesla launched its Robotaxi platform in Austin on June 22 and is expanding access to more members of the public. Austin residents are now reporting that they have been invited to join the program.
Elon Musk
Tesla surges following better-than-expected delivery report
Tesla saw some positive momentum during trading hours as it reported its deliveries for Q2.
Tesla (NASDAQ: TSLA) surged over four percent on Wednesday morning after the company reported better-than-expected deliveries. It was nearly right on consensus estimations, as Wall Street predicted the company would deliver 385,000 cars in Q2.
Tesla reported that it delivered 384,122 vehicles in Q2. Many, including those inside the Tesla community, were anticipating deliveries in the 340,000 to 360,000 range, while Wall Street seemed to get it just right.
Tesla delivers 384,000 vehicles in Q2 2025, deploys 9.6 GWh in energy storage
Despite Tesla meeting consensus estimations, there were real concerns about what the company would report for Q2.
There were reportedly brief pauses in production at Gigafactory Texas during the quarter and the ramp of the new Model Y configuration across the globe were expected to provide headwinds for the EV maker during the quarter.
At noon on the East Coast, Tesla shares were up about 4.5 percent.
It is expected that Tesla will likely equal the number of deliveries it completed in both of the past two years.
It has hovered at the 1.8 million mark since 2023, and it seems it is right on pace to match that once again. Early last year, Tesla said that annual growth would be “notably lower” than expected due to its development of a new vehicle platform, which will enable more affordable models to be offered to the public.
These cars are expected to be unveiled at some point this year, as Tesla said they were “on track” to be produced in the first half of the year. Tesla has yet to unveil these vehicle designs to the public.
Dan Ives of Wedbush said in a note to investors this morning that the company’s rebound in China in June reflects good things to come, especially given the Model Y and its ramp across the world.
He also said that Musk’s commitment to the company and return from politics played a major role in the company’s performance in Q2:
“If Musk continues to lead and remain in the driver’s seat, we believe Tesla is on a path to an accelerated growth path over the coming years with deliveries expected to ramp in the back-half of 2025 following the Model Y refresh cycle.”
Ives maintained his $500 price target and the ‘Outperform’ rating he held on the stock:
“Tesla’s future is in many ways the brightest it’s ever been in our view given autonomous, FSD, robotics, and many other technology innovations now on the horizon with 90% of the valuation being driven by autonomous and robotics over the coming years but Musk needs to focus on driving Tesla and not putting his political views first. We maintain our OUTPERFORM and $500 PT.”
Moving forward, investors will look to see some gradual growth over the next few quarters. At worst, Tesla should look to match 2023 and 2024 full-year delivery figures, which could be beaten if the automaker can offer those affordable models by the end of the year.
Tesla begins expanding Robotaxi access: here’s how you can ride
Tesla analyst issues stern warning to investors: forget Trump-Musk feud
Tesla surges following better-than-expected delivery report
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