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.
SpaceX reached an incredible milestone with its Starlink program with a launch last night, as the 3,000th satellite of the year was launched into low Earth orbit.
On Monday, SpaceX also achieved its 32nd flight with a single Falcon 9 rocket from NASA’s Kennedy Space Center.
The mission was Starlink 6-92, and it utilized the Falcon 9 B1067 for the 32nd time this year, the most-used Falcon booster. The flight delivered SpaceX’s 3000th Starlink satellite of the year, a massive achievement.
There were 29 Starlink satellites launched and deployed into LEO during this particular mission:
Falcon 9 launches 29 @Starlink satellites from Florida pic.twitter.com/utKrXjHzPN
— SpaceX (@SpaceX) December 9, 2025
SpaceX has a current goal of certifying its Falcon boosters for 40 missions apiece, according to Spaceflight Now.
The flight was the 350th orbital launch from the nearby SLC-40, and the 3,000 satellites that have been successfully launched this year continue to contribute to the company’s goal of having 12,000 satellites contributing to global internet coverage.
There are over five million users of Starlink, the latest data shows.
Following the launch and stage separation, the Falcon 9 booster completed its mission with a perfect landing on the ‘Just Read the Instructions’ droneship.
The mission was the 575th overall Falcon 9 launch, highlighting SpaceX’s operational tempo, which continues to be accelerated. The company averages two missions per week, and underscores CEO Elon Musk’s vision of a multi-planetary future, where reliable connectivity is crucial for remote work, education, and emergency response.
As Starlink expands and works toward that elusive and crucial 12,000 satellite goal, missions like 6-92 pave the way for innovations in telecommunications and enable more internet access to people across the globe.
With regulatory approvals in over 100 countries and millions of current subscribers, SpaceX continues to democratize space, proving that reusability is not just feasible, but it’s also revolutionary.
Tesla expanded its new Full Self-Driving program, which gives people the opportunity to experience the company’s suite, in Europe.
Tesla recently launched an opportunity for Europeans to experience Full Self-Driving, not in their personal vehicles, but through a new ride-along program that initially launched in Italy, France, and Germany back in late November.
People could experience it by booking a reservation with a local Tesla showroom, but timeslots quickly filled up, making it difficult to keep up with demand. Tesla expanded the program and offered some additional times, but it also had its sights set on getting the program out to new markets.
It finally achieved that on December 9, as it launched rides in Denmark and Switzerland, adding the fourth and fifth countries to the program.
Tesla confirmed the arrival of the program to Denmark and Switzerland on X:
Now available in Denmark & Switzerland
🇩🇰 https://t.co/IpCSwHO566 https://t.co/V2N5EarLNX
— Tesla Europe & Middle East (@teslaeurope) December 9, 2025
The program, while a major contributor to Tesla’s butts in seats strategy, is truly another way for the company to leverage its fans in an effort to work through the regulatory hurdles it is facing in Europe.
Tesla has faced significant red tape in the region, and although it has tested the FSD suite and been able to launch this ride-along program, it is still having some tremendous issues convincing regulatory agencies to allow it to give it to customers.
CEO Elon Musk has worked with regulators, but admitted the process has been “insanely painful.”
The most recent development with FSD and its potential use in Europe dealt with the Dutch approval authority, known as the RDW.
Tesla says Europe could finally get FSD in 2026, and Dutch regulator RDW is key
Tesla said it believes some regulations are “outdated and rules-based,” which makes the suite ineligible for use in the European jurisdiction.
The RDW is working with Tesla to gain approval sometime early next year, but there are no guarantees. However, Tesla’s angle with the ride-along program seems to be that if it can push consumers to experience it and have a positive time, it should be easier for it to gain its footing across Europe with regulatory agencies.
News
Tesla ramps hiring for Roadster as latest unveiling approaches
Tesla published three new positions for the Roadster this week, relating to Battery Manufacturing, General Manufacturing, and Vision Engineering.
Tesla is ramping up hiring for positions related to the Roadster program, the company’s ultra-fast supercar that has been teased to potentially hover by CEO Elon Musk.
The company seems to be crossing off its last handful of things before it plans to unveil the vehicle on April Fool’s Day, just about four months away.
Tesla published three new positions for the Roadster this week, relating to Battery Manufacturing, General Manufacturing, and Vision Engineering. All three are located in Northern California, with two being at the Fremont Factory and the other at the company’s Engineering HQ in Palo Alto.
Technical Program Manager, Battery Manufacturing
Located in Fremont, this role specifically caters to the design of the Roadster to factory operations. It appears this role will mostly have to do with developing and engineering the Roadster’s battery pack and establishing the production processes for it:
“You will foster collaboration across design engineering, manufacturing, quality, facilities, and production to align with company priorities. Additionally, you will understand project opportunities, challenges, and dependencies; translate scattered information into concise, complete messages; and communicate them to every team member. As the business process development lead, you will develop, maintain, and implement tools and processes to accelerate battery manufacturing execution, achieve cross-functional alignment, and deliver highly efficient systems.”
Manufacturing Engineer, Roadster
Also located in Fremont, this role also has to deal with the concept development and launch of battery manufacturing equipment. Tesla says:
“In this role, you will take large-scale manufacturing systems for new battery products and architectures from the early concept development stage through equipment launch, optimization, and handover to local operations teams.”
Manufacturing Vision Engineer, Battery Vision
This position is in Palo Alto at Tesla’s Engineering Headquarters, and requires the design and scale of advanced inspection and control systems to next-generation battery products:
“You’ll work on automation processes that directly improve battery performance, quality, and cost, collaborating with world-class engineers in a fast-paced, hands-on environment.”
Developing and deploying 2D and 3D vision and measurement systems from proof-of-concept to deployment on high-volume battery manufacturing lines is part of the job description.
Roadster Unveiling
Tesla plans to unveil the Roadster on April 1, and although it was planned for late this year, it is nice to see the company put out a definitive date.
Musk said on the Joe Rogan Experience Podcast in late October:
“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 unveil ever.”
Production should begin between 12 to 18 months after unveiling, so we could see it sometime in 2027.
SpaceX reaches incredible milestone with Starlink program
Tesla expands new Full Self-Driving program in Europe
