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SpaceX’s 2018 Crew Dragon launch debut imminent as spacecraft hardware comes together

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SpaceX’s first spaceworthy Crew Dragon spacecraft officially has a confident launch target in hand as a flood of activity has begun to complete, ship, test, and deliver multiple critical components ranging from the Dragon capsule itself to the Falcon 9 Block 5 first and second stages for that capsule’s November or December launch debut.

As of today, SpaceX has between three and four months to finish up a significant – but by no means impossible – amount of work, ranging from actual hardware completion, integration, and preflight checkouts and testing to a veritable flood of paperwork required by NASA before any Commercial Crew launch can proceed.

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Paper beats rock(et)

In fact, given comments from SpaceX’s President and COO Gwynne Shotwell and CEO Elon Musk, the executives appeared to be very confident that the hardware for the first uncrewed demo mission (DM-1) and second crewed test flight (DM-2) would be ready for launch. These comments most likely group software under that hardware umbrella, meaning that Shotwell and Musk seem to be very subtly commenting on the immense bureaucratic workload required from SpaceX before NASA will permit them to launch.

Decades of experience as a military-industrial complex stalwart has readily prepared Boeing to deal with those vast ‘certification’ workloads, but that certainly doesn’t mean that NASA couldn’t find a more pragmatic and less oppressive balance between carelessness and a downright obsessive compulsion to document every molecule of their commercial providers’ hardware, software, and wetware (employees, management, organizational structure).

Falcon 9 preps for Crew Dragon

Despite the often-onerous bureaucratic demands of NASA’s Commercial Crew Program office, SpaceX is moving rapidly ahead with a range of hardware, all critical for the Crew Dragon’s November/December launch debut. With the capsule itself already in Florida and the DM-1 Dragon’s trunk nearing shipment from Hawthorne to Cape Canaveral (currently NET September), the next and perhaps most important piece is Falcon 9 itself.

Confirmed earlier this year in a quarterly NASA Commercial Crew update, SpaceX assigned Falcon 9 Booster 1051 to Crew Dragon’s debut launch. That rocket booster and its complementary upper stage are already at SpaceX’s McGregor, TX rocket testing facility undergoing a number of acceptance tests and checkouts as of today, confirming a number of critical facts. Most importantly, the presence of integrated the B1051 booster in Texas appears to imply that SpaceX has successfully fixed slight design flaws in their Merlin 1D engines and composite-overwrapped pressure vessels (COPVs), even if the paperwork to officially ‘certify’ them for flight has not been completed.

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This meshes nicely with details provided in a recent NASA Commercial Crew news post, which stated that “Falcon 9’s first and second stages for the Demo-1 [Crew Dragon] mission are targeted to ship … [to] McGregor, Texas for additional testing in August.” Ship they did and the booster may well have beaten that “August” timeframe according to photos of the facility from mid-July. When exactly that testing will wrap up in Texas is unclear but it would be reasonable to expect the rocket booster and upper stage to ship to SpaceX’s Launch Complex 39A (LC-39A) in Cape Canaveral within 4-6 weeks, giving the company a solid month and a half to integrate the rocket, static fire it at the pad, complete assembly of Crew Dragon, and attach the spacecraft to its Falcon 9 rocket ahead of launch.


For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet (including fairing catcher Mr Steven) check out our brand new LaunchPad and LandingZone newsletters!

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Eric Ralph is Teslarati's senior spaceflight reporter and has been covering the industry in some capacity for almost half a decade, largely spurred in 2016 by a trip to Mexico to watch Elon Musk reveal SpaceX's plans for Mars in person. Aside from spreading interest and excitement about spaceflight far and wide, his primary goal is to cover humanity's ongoing efforts to expand beyond Earth to the Moon, Mars, and elsewhere.

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Tesla just told us twice that Model Y L is coming to the U.S.

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Credit: Tesla

Tesla just told us twice that the Model Y L is coming to the U.S., and two social media posts definitely just tipped the company’s hand, as if they wanted it to be any other way.

The two social media posts basically confirm that the slightly longer version of the Model Y will be heading to the United States soon, and many have speculated that the company could launch the vehicle as soon as this weekend.

The first post was directly from Tesla, and it showed an incredibly long Dachshund, with words above that said, “Looking forward to the long weekend.”

Anyone who knows Tesla knows the company loves to troll its fans and have fun, and this is a perfect example of that. While not a direct acknowledgement, Tesla is very involved on social media, especially CEO Elon Musk’s platform X, and the company is well aware of what is being discussed within the community.

With recent sightings of Model Y L test mules in California, peeks of the vehicle at Giga Texas, and a large call for the car to come to the U.S., Tesla is simply stoking conversation with this.

However, the company also made another move that was recognized on social media. Tesla has a large gallery that includes photos of its products so media and others can use them. This gallery applies to the U.S. market specifically, unless otherwise specified.

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Tesla uploaded a Model Y L to the Gallery last night:

This seems to be another indication that the Model Y L is coming to the United States.

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Musk said last year that the Model Y L could make its way to the United States late this year, but it was not something that was set in stone by Tesla. The company definitely needs to establish something in the SUV market that is larger than the Model Y, and the Model Y L might be the answer.

Even still, there are consumers out there who would love Tesla to develop something even larger, like a competitor to the Tahoe or Expedition. Tesla has not really given much of an indication that it will go in that direction.

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Tesla is using vehicle microphones to improve build quality: here’s how

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Credit: Tesla

Tesla is using the vehicles’ internal microphones to improve build quality, Vice President of Engineering Lars Moravy revealed recently.

It’s no secret that Tesla is always finding ways to make its manufacturing operations more efficient, accurate, and valuable. Constantly trying to make its cars better, the company has never placed any restrictions on what it will do to improve everything from panel gaps to paint.

As Teslas have been driving autonomously on the property of the Gigafactory Texas plant for a while now, Moravy revealed to Herbert Ong in a new interview that cars rolling off production lines now autonomously navigate themselves through a bumps, squeaks, and rattles (BSR) portion of the line. This helps to identify any loose or improperly installed internal parts.

The cabin’s microphones, which are used for a variety of things in ownership, simultaneously monitor any noises inside the vehicle while it rolls through the BSR portion of the production line. Moravy actually revealed that Tesla is trying to build “Full Self-Hearing,” an AI system that will detect minor imperfections so they can be corrected before delivery.

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It’s no secret that build quality is something that Tesla struggled with as it scaled to a fully massive production operation that manufactures over 1.6 million vehicles per year. However, in recent years, especially, there have not been as many complaints. Tesla has truly improved upon its build quality and paint quality over the past several years, especially in the U.S.

Tesla’s ‘megacasts’ are key to massive build quality improvements

While those improvements have been evident, there are still some complaints; no automaker is perfect with this. But this step will now ensure that every single car that rolls off the production lines at Gigafactory Texas will be void of any creaks, squeaks, or squeals when it leaves the factory.

This measure is one of the most unique we’ve seen in terms of a strategy to avoid build quality issues, but it is not exclusive to Tesla.

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Ford uses acoustic analysis AI to find abnormalities in seat motors, climate control units, and other components. Suppliers and OEMs will also use microphone arrays or particle velocity sensors in end-of-line stations.

The full interview with Lars Moravy is available below:

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Investor's Corner

Tesla crushes Wall Street expectations, beats delivery estimates by over 15 percent

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Tesla (NASDAQ: TSLA) beat Wall Street expectations of 406,000 vehicles delivered in Q2 by reporting 480,126 deliveries for the three months ending in June.

Tesla reported it delivered 467,762  Model 3 and Model Y units, while 12,364 Model S, Model X, and Cybertrucks switched hands during the quarter. The Model S and Model X were officially sunset this past quarter and will no longer be part of the company’s Production & Delivery reports moving forward.

The quarter is a pleasant surprise and a good rebound from Q1, when Tesla slightly missed the Wall Street consensus of 365,645 cars by reporting 358,023 deliveries for the first three motnhs of the year.

Energy storage deployments also provided some strength in Tesla’s delivery report, hitting 13.5 GWh for Q2. This is a particular division of Tesla’s business that has been overwhelmingly robust over the past few years, truly being a strong point of the company’s overall model.

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For the year, Tesla analysts still predict deliveries to trend in the 1.69 million unit region, a modest 3 to 5 percent increase from the 1.64 million cars the company delivered last year. Tesla will likely return to more sequential and noticeable year-over-year growth as the Cybercab project starts to ramp up considerably in the next few years.

Tesla has some other potential catalysts to spur vehicle deliveries, too. Not only is it expecting Cybercab to truly start making a change in the next few years, but other vehicles could be entering the company’s lineup.

Tesla sends production Cybercab with no steering wheel, pedals to on-road testing

The slightly longer Model Y L has been a highly speculated release candidate in the U.S. It has already done incredibly well in China, and U.S. buyers have been wanting slightly more interior space than the Model Y. Now that the Model X is gone, it is more needed than ever.

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Q2 highlights a pretty stable automotive division within Tesla, and no true concerns arise from these figures, especially considering it managed to beat expectations convincingly.

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