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SpaceX’s Crew Dragon just became America’s longest-lived astronaut spaceship

NASA's SpaceX Crew-1 astronauts celebrated a new record today, making Crew Dragon the longest-lived American astronaut spacecraft ever. (NASA)

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SpaceX’s Crew Dragon has officially become the longest-lived American astronaut spacecraft ever built, beating an 84-day record set by the Apollo-era Skylab-4 mission almost half a century ago.

Crew Dragon was able to beat that record so quickly because NASA ultimately chose to cannibalize its existing Saturn rocket and Apollo CSM spacecraft expertise, production capabilities, and budget to go all-in on the Space Shuttle program. Meant to be quickly and cheaply reusable, a wide range of compromises, budget shortfalls, and design-by-committee missteps ultimately produced a Shuttle that was horrifically complex, unsafe, only partially reusable, suboptimal for most tasks, and more expensive to launch than Saturn V.

The Space Shuttle was ultimately a beast to refurbish and “reuse”, often requiring an almost complete disassembly and reassembly and extensive rework on most propulsive components. Partially due to those extreme shortcomings and a catastrophically fatal launch failure just five years after its debut, the Shuttle was never able to get anywhere close to realizing its limited but still strong potential, including a maximum orbital longevity of just two or so weeks.

Skylab-4’s command and service module (CSM) spacecraft is pictured during a February 1974 EVA. (NASA)
SpaceX’s privately-developed Crew Dragon is now the new record-holder for crewed American spacecraft longevity. (NASA)

As a result, NASA went from Saturn I, Saturn V, and CSM – a combination that enabled single-launch space stations, multi-month crewed spaceflights, and the Apollo Program – to the Space Shuttle, an anchor that yanked the space agency’s human agency ambitions back to low Earth orbit (LEO). In the Space Shuttle’s defense, NASA did eventually join an international initiative to build the International Space Station (ISS), a program the Shuttle supported with several dozen launches of crucial modules, components, and supplies.

However, had NASA been able to continue the Skylab program with Saturn and CSM, a space station with a habitable volume similar to the 2021 ISS could have been completed in a mere three launches, compared to no less than 30 launches to build the ISS.

https://twitter.com/enterprise_flt/status/1358415793885691904

Regardless, after an unfortunate and unnecessary 47-year pause, SpaceX – with NASA funding – has returned the space agency and the US to its legacy of envelope-pushing. On the heels of 20 successful uncrewed Cargo Dragon missions to and from the ISS over the last 9 years, all of which spent around a month in orbit, SpaceX’s third Crew Dragon launch has already beat the US record for crewed spacecraft longevity on orbit and is ultimately poised to double it before the mission’s end.

Crew Dragon’s Crew-1 astronauts even celebrated the milestone in orbit with (albeit virtually) Ed Gibson, one of the three astronauts that set Skylab-4’s record 47 years prior. Additionally, in a pleasing coincidence, Skylab-4 and SpaceX Crew-1 nearly launched on the same day, meaning that tomorrow (February 8th) is the true 47th anniversary of the Skylab-4 mission’s reentry and splashdown.

SpaceX successfully returned two NASA astronauts to Earth in August 2020. (NASA/SpaceX)

All told, all operational Crew Dragon missions – of which Crew-1 is the first – are scheduled to spend approximately 180 days in orbit between launch and reentry. As the first US spacecraft (and first private spacecraft) to attempt such a long spaceflight, there is obviously some uncertainty and no guarantee that this first try won’t be cut short, but odds are in SpaceX’s favor that Crew Dragon capsule C207 will depart the ISS without issue and safely return its four-astronaut crew back to Earth sometime in May 2021.

Carrying two humans, Crew Dragon floats back to Earth under four massive parachutes. (NASA/Bill Ingalls)

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 Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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SpaceX has solved Starship’s biggest challenge, Elon Musk says

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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