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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.
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These Tesla Superchargers are free today for Earth Week
Canada and other countries are missing on the free Earth Week Supercharging map, while the U.S. state of California gets the promo at two sites.

Tesla has made several of its Supercharging stations free in markets around the world over the weekend, in order to commemorate Earth Day, which took place earlier this week.
On Friday, Tesla posted on its charging account on X that it would be offering free Supercharging across 30 select stations on Saturday in celebration of Earth Day and Week. The chargers are set to be free during daytime work hours, and they’re scattered in locations across Europe, North America, and the Asia-Pacific region.
Tesla also says it may have employees handing out “goodies” at some of the sites, though the company didn’t disclose what they would be.
“Closing out Earth Week with free charging at the following Superchargers on April 26th,” Tesla writes. “You might even catch some Tesla employees with goodies!”
In the U.S., the Supercharger stations offering free charging include two located in California, along with one each in Florida, Arizona, Illinois, and New Jersey. The company is also offering free Supercharging in Nuevo León, Mexico, in the city of Monterrey.
You can see the full list of free Supercharger locations below, along with the times the offer is still available on Saturday.
READ MORE ON TESLA SUPERCHARGERS: Tesla’s Hollywood Diner is finally getting close to opening
Tesla Superchargers offering free charging on Saturday, April 26
Europe (9:00 a.m. to 6:00 p.m.)
- Cork, Ireland
- London, UK – Gatwick
- Leeds, United Kingdom
- Aalborg, Denmark
- Rødovre, Denmark
- Espoo, Finland
- Tampere, Finland
- Löddeköpinge, Sweden
- Mantorp, Sweden
- Hamburg, Germany
- Hilden, Germany
- Köln – Carlswerk, Germany
- Dietikon, Switzerland
- Warsaw, Poland – Radzymińska
- Les Pennes-Mirabeau, France
- Montélimar, France
- Jamné, Czech Republic
North America (9:00 a.m. to 6:00 p.m.)
- Santa Monica, CA
- Kettleman City, CA
- Phoenix, AZ – East Mayo Boulevard
- Des Plaines, IL
- Fort Pierce, FL – Peters Road
- Mount Laurel Township, NJ – NJ-73
- Monterrey, NL
Asia-Pacific
- Singapore – Tesla Centre Toa Payoh (10:00 a.m. to 7:00 p.m.)
- Georgetown, Malaysia – Gurney Plaza (10:00 a.m. to 10:00 p.m.)
- Samut Prakan, Thailand – Mega Bangna – IKEA Carpark (10:00 a.m. to 10:00 p.m.)
- Mandaluyong, Philippines – Shangri-La Plaza (10:00 a.m. to 10:00 p.m.)
- Seoul Gangnam, South Korea – Construction Building Floor G (9:00 a.m. to 7:00 p.m.)
- Taipei, Neihu – Service Centre (9:00 a.m. to 7:00 p.m.)
Tesla’s Superchargers in North America opening to non-Tesla EVs
Along with allowing Tesla’s vehicles to charge at Supercharger stations, the company has slowly been rolling out access to other, non-Tesla electric vehicle (EV) brands in North America over the past several months. For example, Superchargers opened to Kia’s EVs in North America on Thursday, increasing the company’s chargers to the over 40,000 DC fast-charging stations and doubling the number of stations owners of the car brand can use.
Other brands with access to Tesla’s Superchargers include Kia parent company Hyundai, Ford, GM, Genesis, Lucid, Mercedes, Nissan, Polestar, Rivian, and Volvo, and Volkswagen and subsidiary Audi are the next brands in line to gain access.
Tesla also runs three-month Supercharger voting periods for owners to cast votes on where they’d like to see new Superchargers built, and the company recently opened its voting round for the second quarter along with revealing the winning locations from Q1.
Tesla Superchargers were over 10 times as reliable as these rivals
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Tesla Model Y and Model 3 still kings of Europe BEVs in March 2025: JATO
The Tesla Model 3 and Model Y remained the kings of Europe’s battery electric vehicle sector in March 2025.

Reports of Tesla’s death in Europe have been wildly exaggerated. This was recently highlighted by JATO Dynamics, which noted that Tesla’s decline in Europe actually slowed down in March.
As per JATO Dynamics data, the Tesla Model 3 and Model Y also remained the kings of Europe’s battery electric vehicle sector in March 2025.
Tesla Europe’s Q1 2025
Tesla’s decline in January and February 2025 in Europe has resulted in quite a lot of alarmist reports about the electric vehicle maker. While Tesla noted in its Q1 vehicle delivery report that its sales decline was mostly due to the changeover to the new Model Y, critics nonetheless argued that Tesla’s brand has been utterly destroyed by the politics of CEO Elon Musk.
A look at JATO’s recent report, however, suggests that Tesla is starting to show some recovery in Europe. While Tesla saw a 38% year-over-year decline in the first quarter overall, the company’s drop became less severe as the quarter ended. In January, Tesla Europe recorded a severe 47% drop, and in February, the company’s year-over-year decline dropped to 44%. In March, Tesla Europe’s year-over-year decline had dropped to just 30%.
Interestingly, Felipe Munoz, Global Analyst at JATO Dynamics, noted that the Tesla Model 3 became a valuable player in the company’s Europe numbers in March. “As the brand continues to deal with a host of PR issues in addition to the changeover of the Model Y, Tesla is now relying on the Model 3 to offset the losses,” Munoz stated.
Tesla Model Y and Model 3 Still Dominates
Granted, Tesla’s decline in the first quarter in Europe paved the way for Volkswagen to become the region’s top BEV seller for Q1. However, when it came to the sales of individual BEVs in the region, the Tesla Model Y and Model 3 remained unstoppable. What was especially interesting was the fact that the Model Y and Model 3 topped Europe’s battery electric vehicle rankings in March despite the vehicles seeing a year-over-year decline in sales.

The Model Y topped Europe’s best-selling BEV list in March with a total of 15,164 units sold. Following the Model Y was the Model 3, which saw a total of 12,500 units sold in March. The mass market Tesla siblings’ sales figures were notably higher than their closest competitors. The Volkswagen ID.4, which was ranked 3rd, only saw sales of 7,675 units, and the Volkswagen ID.7, the 4th-best-selling BEV in Europe in March, only sold 7,438 units during the month.
“Despite the controversy surrounding the brand’s CEO and the limited availability of the new Model Y, Tesla continues to perform well as the most popular EV brand in Europe. Its success, amid these challenges, provides an indication of what European consumers are looking for in an EV,” Munoz stated.
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Anti-Elon Tesla sticker maker confirms some customers don’t disapprove of Musk
Some of Hiller’s customers may not necessarily disapprove of Elon Musk’s politics or his work with the Trump administration.

Amidst the ongoing controversies and campaigns against Tesla CEO Elon Musk, Hawaii-based entrepreneur Matthew Hiller has made a killing. Hiller is the man behind some of the most popular anti-Elon Musk stickers that have been spotted in Teslas over the past months.
But in a recent comment to NPR, Hiller shared something rather interesting—some of his customers are purchasing stickers even if they do not necessarily disapprove of Elon Musk.
Business Boom
In a comment to NPR, Hiller, who also works at an aquarium in Hawaii, noted that he listed his first anti-Musk sticker in his online shop MadPufferStickers in 2023. The sticker read, “I bought this before we knew Elon was crazy.” At the time, Hiller noted that Musk was “sort of becoming a bully and sort of pushing disinformation.” While Hiller actually considered buying his own Tesla in the past, Musk’s actions ended up disillusioning him from the company.
“I thought they were very cool. I liked the tech. I liked the fact that they were good for the environment… I mean, some things are more important than just tech, you know, like, I just don’t want to support someone who is so against who I am and what I believe. It was a choice and I didn’t want to be just confused for someone who supported him or agreed with him,” Hiller stated.
The entrepreneur’s sticker business saw a notable boost in recent months, especially following the election of U.S. President Donald Trump. Hiller has since expanded his sticker lineup, with popular ones like “Anti Elon Tesla Club,” “Elon is a dogebag,” and “Elon killed my resale value.” Hiller has sold about 70,000 stickers, magnets, and clings across his online shops on Amazon, Etsy, Redbubble, and eBay so far.
Surprising Clientele
With his business rising, Hiller noted that he has received orders from across the globe, allowing him to reach sales of $100,000 in one month. This was no surprise as Musk has become a controversial figure, not just in the United States but in several countries across Europe as well. When Musk performed his controversial gesture in January alone, Hiller recorded 500 sales in one day.
Most surprisingly, however, some of Hiller’s customers may not necessarily disapprove of Elon Musk’s politics or his involvement with the Trump administration through his work with the Department of Government Efficiency (DOGE). Hiller shared a transaction on his Etsy store to NPR, which involved a sticker that was ordered by a father to his son, who lived in Los Angeles.
“Occasionally, I get people on my Etsy store, they buy a sticker as a gift, and then they get to write a little note along with the gift to the recipient. And occasionally I read the notes and I see one that says like, ‘Happy birthday, from dad. This is to protect you on the mean streets of L.A.,’” Hiller noted.
The customer’s note is not surprising considering that Teslas have been subjected to a wave of vandalism attacks from people or activists who are critical of Elon Musk. The Tesla vandalism incidents, as well as Molotov and shooting attacks on Tesla stores, have been condemned by the Trump administration.
Not a Full-Time Gig
Despite his business boom, Hiller noted that he does not intend to leave his aquarium job yet, nor does he intend to sell stickers full-time. Thus, even if the Elon Musk controversies ended tomorrow, the entrepreneur noted that he would be fine.
“If it ended tomorrow, I’m totally fine. You know, I didn’t set out to do this. And it’s certainly not my business plan going forward. I mean, it’s not a really good business plan to bank on a billionaire just annoying people forever,” Hiller stated.
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