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SpaceX’s Crew Dragon gets tentative NASA target for first astronaut launch

Crew Dragon arrives at the International Space Station for the first time ever during its March 2019 DM-1 mission. (NASA)

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New information from both NASA and the US Government Accountability Office (GAO) confirm that SpaceX is currently targeting – at least very tentatively so – Crew Dragon’s first launch with astronauts aboard no earlier than November 15th, 2019.

SpaceX is currently in the midst of a complex, high-stakes anomaly investigation after its flight-proven DM-1 Crew Dragon capsule suffered a catastrophic failure on April 20th. That investigation is nowhere near full closure due to the fact that the interests of NASA and the Commercial Crew Program (CCP) are equally interwoven into the work involved. Given the potential consequences of a similar failure occurring with astronauts (public or private) aboard, NASA is unlikely to accept anything less than a no-stone-left-unturned analysis and failure resolution, including any necessary design changes to Crew Dragon, no matter how far-reaching.

As NASASpaceflight.com’s Chris Gerbhardt notes, the Crew Dragon-related dates included in the NASA Flight Planning Integration Panel (FPIP) document are extremely tentative. They’re really only there to serve as placeholders for longer-term International Space Station planning, already a necessarily uncertain endeavor. Nevertheless, NASA’s NET November 15th 2019 planning date for Crew Dragon DM-2 (the first crewed test flight) was likely okayed by SpaceX – if not provided outright by the company – before going into an official FPIP.

In other words, November 15th is probably a real target but should be treated as an absolutely-positively-no-earlier-than launch date for Crew Dragon’s first astronaut-laden mission to the ISS. Back in late March (after DM-1’s successfully completion but before the capsule’s ground failure), anonymous Russian space industry sources confirmed that NASA’s DM-2 planning date was July 25th, while also indicating that the space agency was already preparing for delays that could push DM-2 as late as November 2019.

Specifically, an anonymous Roscosmos source told Russian outlet TASS that “the [DM-2] launch of Crew Dragon is likely to be postponed to November”. Given that that delay was rumored – albeit quasi-officially – and reported on nearly a month before Crew Dragon capsule C201 catastrophically exploded during testing, it doesn’t exactly inspire confidence in a November 2019 DM-2 planning date officially released by NASA more three months later.

Crew Dragon stumbles, but optimism remains

As is often said, things were going perfectly up to the point that they weren’t. Despite 2-3 months of NASA paperwork and review-related delays, SpaceX’s first flightworthy Crew Dragon performed flawlessly during orbital rendezvous, docking, departure, and reentry to the extent that NASA and SpaceX officials were joking on-webcast about their partial disbelief. NASA’s lengthy post-mission review effectively concluded as much, although there is always room for improvement.

Due to those aforementioned DM-1 delays (roughly early January to early March), DM-2’s Crew Dragon assembly and integration was delayed in turn to preserve access in case DM-1 revealed flaws or necessary changes. Things didn’t quite go as planned, but the delayed integration has turned out to be beneficial, preserving access to most of Dragon 2’s critical subsystems without requiring major disassembly before any anomaly-related changes are implemented.

A May 2019 NASA update indicated that SpaceX’s DM-2 Crew Dragon (likely the vehicle previously assigned to the subsequent USCV-1 mission) is in the late stages of assembly. Once the anomaly investigation is complete and the DM-2 spacecraft is updated with any necessary modifications, SpaceX will likely require an additional ~4 months of work to reach flight-readiness. (NASA)

Per a late-May update from CCP manager Kathy Lueders, SpaceX has effectively shifted its Crew Dragon hardware assignments over one to account for the loss of the DM-1 capsule, C201. The vehicle previously assigned to DM-2 has been reassigned to a critical in-flight abort (IFA) test, previously meant to use flight-proven C201. Per charts provided during Lueders’ presentation, SpaceX’s replacement DM-2 capsule (likely the capsule previously assigned to the following mission, Crew-1) is in a sort of holding pattern to allow for modifications that may be required after the DM-1 failure investigation concludes.

Per a previous December 2018 update from Lueders, SpaceX’s original DM-2 spacecraft (now assigned to IFA) was expected to be fully assembled, shipped to Pad 39A, and ready for launch by June 2019. Accounting for DM-1’s delays, that spacecraft could likely be ready for the abort test as early as July or August, which meshes with post-anomaly indications that IFA is now scheduled no earlier than fall (September 2019)

Backlit by Earth’s limb, Crew Dragon DM-1’s ISS arrival was captured by astronaut Anne McClain on March 3rd. (NASA/Anne McClain)

All things considered, a pragmatic analysis suggests that Crew Dragon‘s DM-2 launch will most likely happen no earlier than Q1 2020, although miracles (and nightmares) are certainly possible. For the time being, all that really matters to SpaceX is wrapping up the C201 failure investigation as quickly and accurately as possible. Only after the company has publicly announced the results of that investigation should any IFA or DM-2 launch dates be taken with anything less than a full shaker of salt.

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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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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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Investor's Corner

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Investor's Corner

Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

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

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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