News
SpaceX aims to launch critical Crew Dragon abort test before the end of 2019
SpaceX has applied for an FCC Special Temporary Authority license to authorize rocket communications during what is likely Crew Dragon’s In-Flight Abort (IFA) test, now scheduled to occur no earlier than November 23rd.
In line with recent comments from SpaceX executives, a November or December In-Flight Abort test would almost certainly preclude Crew Dragon from launching with astronauts in 2019, pushing the Demo-2 mission into the Q1 2020. Nevertheless, it would serve as a good sign that Crew Dragon remains on track if SpaceX can complete the critical abort test – meant to prove that Dragon can whisk astronauts away from a failing rocket at any point during launch – before the year is out.
The FCC application describes “SpaceX Mission 1357” launch from NASA’s Kennedy Space Center (KSC) Launch Complex 39A, leased by SpaceX and primarily dedicated to launches involving either Falcon Heavy or Crew Dragon. Most tellingly, the STA request describes the mission as involving a “simulated orbital second stage”, an unusual phrase for SpaceX applications that almost certainly reveals it to be Crew Dragon’s IFA.
In the history of Falcon 9, all booster launches from Florida or California have carried functional Falcon upper stages. The FCC application’s “simulated” descriptor implies that this particular mission’s upper stage will not actually be capable of flight – a fact Elon Musk confirmed for the In-Flight Abort test in February 2019. Although the upper stage will otherwise be orbit-capable, the stage on Crew Dragon’s abort test is never meant to ignite and will thus feature a mass simulator in place of a functioning Merlin Vacuum (MVac) engine. A flight-proven Falcon 9 Block 5 booster – likely B1046.4 – will power the mission and both it and the upper stage are very unlikely to survive.
During the In-Flight Abort test, the Falcon 9 stack will lift off like any other launch, flying for approximately 60-70 seconds on a normal trajectory. Shortly thereafter, during a period of peak aerodynamic stress known as Max-Q, Crew Dragon’s SuperDraco abort system will somehow be triggered, causing the spacecraft to rapidly speed away from what it perceives to be a failing rocket. As Crew Dragon departs its perch atop Falcon 9’s upper stage, the rocket’s top will be instantly subjected to a supersonic windstream, akin to smashing into a brick wall. If the upper stage is quickly torn away, the booster will find its large, hollow interstage subjected to the same windstream, likely tearing it apart. The mission will undoubtedly be a spectacle regardless of how things transpire.
This filing comes ahead of the imminent resolution of a multi-month investigation to determine the cause of an anomaly that resulted in the loss of the DM-1 Crew Dragon capsule during a static fire test in April 2019. With that investigation nearly wrapped up and the Florida Department of Environmental Protection declaring “no further action” required with clean up efforts, as reported by Florida Today, SpaceX is likely ready to begin prelaunch preparations for Crew Dragon’s next major milestones.
SpaceX recently posted a video highlighting extensive testing of Crew Dragon’s SuperDraco abort system, noting the thrusters’ ability to propel a Crew Dragon capsule half a mile away from a failing rocket in just 7.5 seconds. SpaceX has performed more than 700 successful static fires, ranging from individual double-engine powerpack tests to a 2015 pad-abort test and integrated hover testing before propulsive Crew Dragon landing development was canceled in 2017.
The late-2019 IFA launch window means that a 2019 crewed Dragon debut is more or less impossible. Nevertheless, if SpaceX can successfully complete Crew Dragon’s IFA test in November or December, chances are good that there will be opportunities to attempt Crew Dragon’s crewed launch debut sometime in Q1 2020.
Check out Teslarati’s Marketplace! We offer Tesla accessories, including for the Tesla Cybertruck and Tesla Model 3.
A California radiologist who drove his Tesla Model Y off a 250-foot cliff in an attempt to kill his family has had his charges dismissed after doctors say he is “doing well” in a mental health program.
Dharmesh Patel was charged with three counts of attempted murder in connection with a January 2023 crash where he drove his Tesla off a cliff, injuring his wife and two children, aged 7 and 4 at the time.
Patel drove the Tesla off Devil’s Slide in California, an area that is extremely rough to the point that investigators and rescuers expected the worst when arriving at the scene for the first time. Patel supposedly had schizoaffective disorder, according to Deputy District Attorney Dominique Davis.
Shockingly, Patel’s wife, who was in the vehicle, testified that she did not want her husband to be prosecuted, noting that their children missed their father and they wanted him to come back home. Patel’s attorney argued, “not everyone who commits a crime is a criminal.”
Doctor who took Tesla off cliff gets support from unlikely person
A three-day trial in Mental Health Diversion Court ruled in Patel’s favor, which kept him out of jail and instead on house arrest. He was admitted to a Mental Health Diversion Program, which he successfully completed, the Associated Press reported. San Mateo County District Attorney Steve Wagstaffe said the judge was “required by law” to dismiss the charges:
“If the person who’s given mental health diversion follows the treatment plan, there’s nothing that can be done, and at the end of the two years he gets it wiped out of his record.”
Wagstaffe said he has argued, along with other DAs in California, to have attempted murder removed from the list of charges eligible to be dismissed due to mental health diversion programs.
Patel had the charges officially dismissed on Monday; his wife waited for him as he left court and they departed the building together, according to Mercury News. Patel surrendered his California medical license in December.
The crash has been one of the best examples of Tesla’s incredible engineering, which has saved four lives in this particular instance. The car was totalled but kept the four human beings alive and safe, which is something that many referred to as “an absolute miracle.”
A common misconception of anti-EV proponents is that the batteries used in the vehicles are detrimental to the environment and that they cause more waste than they are worth. But a look at Tesla’s battery recycling efforts last year shows the company is doing more than ever to recover materials and give portions of the cells a second life.
Tesla reported a significant milestone in its sustainability efforts last year, with battery recycling volumes rising 20% compared to 2024. According to the company’s 2025 Impact Report, Tesla recycled over 14,000 metric tons of battery material through a combination of in-house processing at its Gigafactories and collaborations with third-party recycling partners.
Tesla: “In 2025, we recycled over 14,000 metric tons of battery material through a combination of in-house processing and through our network of recycling partners.”
That’s equivalent to 46,000 long-range battery packs, a +20% increase from 2024. pic.twitter.com/TC3Nz7Kaqf
— Sawyer Merritt (@SawyerMerritt) July 7, 2026
This amount of recovered material is equivalent to the resources needed to produce approximately 46,000 long-range battery packs. The increase reflects growing operational scale as Tesla’s global vehicle fleet expands and more batteries reach end-of-life or manufacturing scrap becomes available for processing.
Tesla and Battery Recycling
Battery recycling forms a core part of Tesla’s circular economy strategy. The company designs its batteries for longevity, often exceeding 200,000 miles of driving, and prioritizes repairs, remanufacturing, and second-life applications before full recycling.
Once packs are decommissioned, Tesla ensures 100% are recycled with no materials sent to landfills. This approach recovers critical metals including lithium, nickel, cobalt, and copper, which can be refined and reused in new battery production.
Tesla has advanced hydrometallurgical recycling processes capable of achieving recovery rates up to 98% for key battery metals. These methods are more efficient and environmentally friendly than traditional pyrometallurgical techniques, reducing energy use and enabling higher-purity materials suitable for direct reintegration into battery manufacturing.
Tesla co-founder JB Straubel confirms Redwood’s battery recycling operations are already profitable
In-house capabilities are supplemented by a network of specialized partners, creating a robust system that handles both production scrap and end-of-life packs.
The environmental and economic benefits are substantial. Recycling reduces reliance on virgin mining, lowers the carbon footprint associated with raw material extraction and processing, and helps stabilize supply chains for critical minerals amid rising global EV demand. As millions of Tesla vehicles age, the volume of recyclable material is expected to grow significantly in the coming years.
This 20% year-over-year growth demonstrates the effectiveness of Tesla’s investments in recycling infrastructure and technology. It positions the company as a leader in addressing one of the automotive industry’s major sustainability challenges. Continued innovation in battery design for easier disassembly and higher recyclability will further enhance these efforts.
Overall, Tesla’s progress in 2025 highlights how scaling recycling operations supports both environmental goals and long-term business resilience in the transition to electric mobility. As the EV market matures, such closed-loop systems will become increasingly vital for sustainable growth.
Tesla has spent years trying to engineer its way out of the automotive paint shop, one of the most expensive, space-consuming, and environmentally costly steps in vehicle manufacturing. With the Cybercab, Tesla confirmed on X this week that a new reaction injection molding process will embed color directly into the panel itself during production.
“Our new reaction injection molding (RIM) process shrinks Cybercab paint cycles from hours to minutes. This cuts those parts’ manufacturing and supply chain emissions by 35% and eliminating 100% of paint volatile organic compounds (VOCs) emitted in traditional paint methods.” noted Tesla.
While the RIM process isn’t necessarily new and has existed since the 1960s, what makes Tesla’s application notable is how it is being used specifically for exterior body panels that traditionally required a separate paint process after forming.
Tesla’s RIM approach integrates the color directly into the panel material during the molding process itself. The pigment is part of the polymer mix injected into the mold, meaning the panel comes out of the mold already colored, with no separate paint application required. The clear coat or protective layer can be applied at the mold stage or through a much faster post-process than traditional multi-stage painting. Tesla claims this compresses what was a multi-hour paint cycle into minutes per panel.
Tesla’s obsession with killing the paint shop is one of the most consistent threads running through the company’s manufacturing philosophy going back years. As far back as 2018, Musk was trimming paint color options to simplify production, tweeting at the time: “Moving 2 of 7 Tesla colors off menu on Wednesday to simplify manufacturing.” Two years later, in a 2020 Automotive News interview, Musk laid out his broader vision, saying he believed Tesla factories could one day be 1,000 times more efficient than conventional plants, and pointing to the paint shop as one of the biggest sources of waste, cost, and complexity. The Cybertruck was the most extreme expression of that thinking. Tesla chose an unpainted stainless steel exterior partly because it would eliminate the need for a $200 million paint facility at Gigafactory Texas. The stainless approach proved harder and more expensive than anticipated, but the underlying ambition never changed. The Cybercab is what happens when that same ambition meets a manufacturing process that delivers on it.
Radiologist who drove Tesla off cliff has attempted murder charges dismissed
Tesla battery recycling efforts increased 20 percent last year
