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SpaceX’s first Crew Dragon NASA astronauts suit up for spacesuit-focused launch rehearsal

On July 31st, NASA astronauts Bob Behnken and Doug Hurley completed a dress rehearsal for their upcoming Crew Dragon Demo-2 launch debut. (SpaceX/NASA)

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While a great deal of work remains before SpaceX and NASA are ready to set a date for Crew Dragon’s inaugural astronaut launch (Demo-2) both teams continue to actively prepare for the milestone mission.

Most recently, NASA has published photos detailing a critical (and literal) dress rehearsal with astronauts Col. Bob Behnken and Col. Doug Hurley, set to become the first astronauts to ride SpaceX’s Crew Dragon to orbit and dock with the International Space Station (ISS). This particular test centered around the process of suiting up in SpaceX’s iconic, custom-built spacesuits and simulated pre-launch procedures in a Crew Dragon simulator located at SpaceX’s Hawthorne, CA headquarters.

A literal dress rehearsal

On Thursday, an official NASA Astronaut account tweeted that SpaceX’s first two Commercial Crew astronauts had recently completed a dress rehearsal test of the spacesuits that they will wear during Crew Dragon’s inaugural crewed launch to the ISS. Bob Behnken and Doug Hurley participated in a full “suit-up & leak checks” rehearsal with their iconic SpaceX-built suits and the same Ground Support Equipment (GSE) hardware that will be used during Demo-2. This dress rehearsal also serves to familiarize the SpaceX and NASA ground support crew with the astronaut suit-up process, and multiple technicians and flight engineers are visible in the background.

The new spacesuits made their press debut last summer at a media event held at SpaceX headquarters in Hawthorne, California. Not only are they uniquely beautiful and modernist, but SpaceX’s spacesuits are also designed first and foremost with functionality in mind. SpaceX hired its own team of seamstresses and focused heavily on integrating 3D printing into suit production, resulting in an end-product that is simultaneously strikingly minimalistic and extremely usable. For example, the helmets Behnken and Hurley are seen wearing use 3D printing to integrate extremely complex life support systems, a built-in microphone and speaker communications array, a seamless multi-hinged visor, and more. 

Portraits of Crew Dragon Demo-2’s main and backup NASA astronauts. From left to right: Bob Behnken, Doug Hurley, Victor Glover, and Mike Hopkins. (SpaceX, April 2019)
Demo-2 astronauts Bob Behnken and Doug Hurley train for their first flight in Crew Dragon. (NASA)

The suits are also designed to allow for easy maneuverability and a seamless user experience within the Dragon capsule. The attached gloves of the suit use conductive leather to allow the astronauts to interact with the Crew Dragon’s primary controls, a set of large touchscreens. Apple iPads will additionally be mounted directly on the thighs of the astronauts to serve as an even more convenient (and redundant) method of interfacing with Dragon’s controls, among other things.

While the suits are designed to be pressurized to support the astronauts in the event of a life-threatening event that may occur aboard Dragon, they are not meant for spacewalks or prolonged exposure to the vacuum of space.

NASA Commercial Crew astronaut Suni Williams tests SpaceX’s Crew Dragon display controls in April 2018. (NASA/SpaceX)

Behnken, Hurley, and other Commercial Crew astronauts have been included in the development of their suits since day one and each flight suit has been carefully tailored to fit each future Crew Dragon astronaut. Having the opportunity to run through a launch day dress rehearsal allows everyone in the process to become familiarized with the specialized procedures that will occur ahead of boarding the Dragon capsule.

Crew Dragon sidesteps the norm

Unlike previous crewed NASA launches, SpaceX plans to have astronauts board Crew Dragon before launch vehicle fueling begins. This new approach to crew loading has become known as “Load-and-Go.” This procedure is extremely familiar to SpaceX, as the company supercools the liquid oxygen and kerosene propellant used by Falcon 9 and Heavy to significantly improve the performance of both rockets.

SpaceX has made the rational argument that boarding astronauts before fueling is actually significantly safer than the traditional method of ingressing astronauts while the rocket is fully fueled. Once inside Crew Dragon, the spacecraft’s SuperDraco abort system would be armed, theoretically protecting its astronauts from any conceivable explosion-related vehicle failure, whereas a fueled rocket failing during ingress could easily kill anyone in close proximity for the boarding procedure.

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Situated atop Falcon 9, Crew Dragon stands vertical at Pad 39A ahead of the spacecraft’s first uncrewed orbital launch. (SpaceX/NASA)

According to NASA, possible dates for Crew Dragon’s Demo-2 astronaut launch debut are under review. In a mid-July conference call with SpaceX and NASA officials, neither were particularly confident that Demo-2 would be ready to launch before the end of 2019, although they specifically did not rule the possibility out. More likely than not, Crew Dragon Demo-2 will slip into early 2020 as a result of a catastrophic explosion that destroyed Crew Dragon capsule C201 during static fire testing earlier this year.

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Samsung’s Tesla AI5/AI6 chip factory to start key equipment tests in March: report

Samsung Electronics seems to be ramping its efforts to start operations at its Taylor, Texas semiconductor plant.

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Image used with permission for Teslarati. (Credit: Tom Cross)

Samsung Electronics seems to be ramping its efforts to start operations at its Taylor, Texas semiconductor plant, which will produce Tesla’s next-generation AI5 chip. 

Preparing for Tesla’s AI5/AI6 chips

As per a report by Sina Finance, Samsung Electronics is looking to begin trial operations of extreme ultraviolet (EUV) lithography equipment at its Taylor facility in March. These efforts are reportedly intended to support the full production of Tesla’s AI5 chips starting in the latter half of 2026.

The Taylor factory, Samsung’s first wafer fabrication plant in the United States, covers roughly 4.85 million square meters and is nearing completion. Media reports, citing contractors, have estimated that about 7,000 workers now work on the factory, about 1,000 of whom are reportedly working from the facility’s office building. 

Samsung is reportedly preparing to apply for a temporary occupancy permit, which would allow production to begin before the plant is fully completed.

Tesla’s aggressive AI chip roadmap

Elon Musk recently stated that Tesla’s next-generation AI5 chip is nearly complete, while early development on its successor, AI6, is already underway. Musk shared the update in a post on X, which also happened to be a recruiting message for engineers.

As per Musk, Tesla is looking to iterate its in-house AI chips on an accelerated timeline, with future generations, including AI7, AI8, and AI9, targeting a roughly nine-month design cycle. He also stated that the rapid cadence could allow Tesla’s chips to become the highest-volume AI processors in the world.

Previous reports have indicated that Samsung Electronics would be manufacturing Tesla’s AI5 chip, alongside its rival, Taiwan Semiconductor Manufacturing Company (TSMC). The two suppliers are expected to produce different versions of Tesla’s AI5 chip, with TSMC using a 3nm process and Samsung targeting 2nm production.

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Elon Musk’s Boring Company studying potential Giga Nevada tunnel: report

The early-stage feasibility work was funded by a state-affiliated economic group as officials searched for alternatives to worsening traffic and accidents along Interstate 80.

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(Credit: The Boring Company

Elon Musk’s tunneling startup, The Boring Company, has been studying a potential tunnel system connecting Reno to Tesla Gigafactory Nevada, as per documents obtained by Fortune. The early-stage feasibility work was funded by a state-affiliated economic group as officials searched for alternatives to worsening traffic and accidents along Interstate 80.

Potential Giga Nevada tunnel

Documents reviewed by Fortune showed that The Boring Company received $50,000 in October to produce conceptual designs and a feasibility report for a tunnel beneath a nine-mile stretch of highway leading to Gigafactory Nevada. The payment came from the Economic Development Authority of Western Nevada (EDAWN), a nonprofit that works with the state to attract and expand businesses.

The proposed tunnel was one of several transportation alternatives being explored to address rising congestion and accidents along Interstate 80, which serves the Tahoe-Reno Industrial Center. The massive industrial park houses major employers, including Tesla and Panasonic, both of which had been in contact with the Nevada Governor’s Office regarding potential transportation solutions.

Emails obtained through public records requests showed that Tesla and Panasonic have also supported a separate commuter rail study that would use existing freight rail alongside the Interstate. It remains unclear if The Boring Company’s feasibility report had been completed, and key details for the potential project, including tunnel length, cost, and if autonomous Teslas would be used, were not disclosed.

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(Credit: The Boring Company)

Relieving I-80 congestion

Traffic and accidents along I-80 have increased sharply as data centers and new businesses moved into the 107,000-acre industrial center. State transportation data showed that the number of vehicles traveling certain stretches of the highway during peak hours doubled between January and July 2025 alone. Roughly 22,000 employees commute daily to the industrial park, with nearly 8,000 working for Tesla and more than 4,000 for Panasonic at the Giga Nevada complex.

Bill Thomas, who runs the Regional Transportation Commission of Washoe County, shared his thoughts about safety concerns in the area. “At this point in time, there’s about (one accident) every other day,” he said. He also noted that he is supportive of any projects that could alleviate traffic and accidents on the Interstate. 

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“We’re not paying for it. I’m not involved in it. But I understand there are conversations exploring whether that could be done. If there’s a private solution that helps the problem and improves safety, as far as I’m concerned, more power to them,” Thomas stated. 

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Tesla might have built redundancies for Cybercab charging

When Tesla unveiled the Cybercab in 2024, the company noted that the autonomous two-seater would utilize wireless charging.

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Credit: @AdanGuajardo/X

A newly spotted panel on Tesla’s Cybercab prototype may point to a practical backup for the vehicle’s wireless charging system as it nears mass production. 

Tesla watchers have speculated that the panel could house a physical NACS port, which would ensure that the autonomous two-seater could operate reliably even before the company’s wireless charging infrastructure is deployed.

Cybercab possible physical charge port

The discussion was sparked by a post on X by Tesla watcher Owen Sparks, who highlighted a rather interesting panel on the Cybercab’s rear. The panel, which seemed to be present in the prototype units that have been spotted across the United States recently, seemed large enough to house a physical charge port.

When Tesla unveiled the Cybercab in 2024, the company noted that the autonomous two-seater would utilize wireless charging. Since then, however, Tesla has remained largely quiet about the system’s rollout timeline. With the Cybercab expected to enter production in a few months, equipping the vehicle with a physical NACS port would allow it to charge at Superchargers nationwide without relying exclusively on still-undeployed wireless chargers.

Such an approach would not rule out wireless charging long-term. Instead, it would give Tesla flexibility, allowing the Cybercab to operate immediately at scale while wireless charging solutions are rolled out later. For a vehicle designed to operate continuously and autonomously, redundancy in charging options would be a practical move.

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Growing Cybercab sightings

Recent sightings of the Cybercab prototype in Chicago point to the same design philosophy. Images shared on social media showed the vehicle coated in road grime, while its rear camera area appeared noticeably cleaner, with visible traces of water on the trunk.

The observation suggests that the Cybercab is equipped with a rear camera washer. As noted by Model Y owner and industry watcher Sawyer Merritt, this is a feature Tesla owners have requested for years, particularly in snowy or wet climates where dirt and slush can obscure cameras and degrade the performance of systems like FSD.

While only the rear camera washer was clearly visible, the sighting raises the possibility that Tesla may equip additional exterior cameras with similar cleaning systems. For a vehicle that operates without a human driver,  after all, maintaining camera visibility in all conditions is essential. Ultimately, the charge-port speculation and camera-washer sightings suggest Tesla is approaching the Cybercab with practicality in mind.

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