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SpaceX says Crew Dragon parachute upgrade nailed more than a dozen tests in a row

SpaceX says it has successfully completed 13 consecutive tests of Crew Dragon's upgraded 'Mk3' parachutes in the last several weeks. (SpaceX)

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According to SpaceX, Crew Dragon’s upgraded ‘Mk3’ parachutes have successfully completed more than a dozen tests in a row, a feat accomplished by SpaceX engineers and technicians in a single week.

Although SpaceX will likely continue to test the upgraded parachutes over the next several weeks and months, Mk3’s success up to now – including a demonstration of an emergency landing scenario – likely means that the company is well on track for NASA to certify Crew Dragon for its first astronaut launch.

Known as Demo-2, SpaceX’s first crewed demonstration mission is tentatively scheduled to launch no earlier than the first quarter of 2020 and is almost entirely dependent upon NASA (and SpaceX, to a lesser extent) completing review and qualification paperwork. On October 8th, SpaceX CEO Elon Musk indicated that SpaceX itself – including all Crew Dragon and Falcon 9 hardware – would likely be ready to launch before the end of December 2019.

During an October 30th briefing from Commercial Crew Program manager Kathy Lueders, NASA essentially confirmed Musk’s estimate for Crew Dragon hardware readiness, estimating that the Crew Dragon Demo-2 spacecraft will be ready for flight around the end of December. The mission’s Falcon 9 booster has also completed testing in Texas, while SpaceX plans to ship the Falcon 9 upper stage to Texas for acceptance testing in November.

In recent months, NASA has indicated that the parachute systems of both Boeing’s Starliner and SpaceX’s Crew Dragon were a prominent concern after chute failures occurred on several occasions. In response, SpaceX redesigned Crew Dragon’s parachutes – supplied by Airborne Systems – to account for the failure modes experience, while also advancing the state of the art of computer modeling of parachute deployment and behavior.

In response to past failures, SpaceX chose to further upgrade and strengthen Crew Dragon’s parachutes, moving to a ‘Mk3’ variant with stronger Zylon risers (strips connecting Dragon to its parachute rigging), among other tweaks. Notably, in an October 2019 press conference with Musk, NASA administrator Jim Bridenstine noted that SpaceX had plans to field and test those Mk3 parachutes at least 10 times before the end of 2019.

“We could see as many as 10 drop tests between now and the end of the year and depending on how the next 10 drop tests go, we will know how many more drops tests we are going to add.”

Jim Bridenstine, October 10th, 2019

In fact, during the latest stage of testing, SpaceX says it successfully completed thirteen consecutive tests of Crew Dragon’s new Mk3 parachutes, all of which were completed in less than two weeks. This essentially blows Bridenstine’s expectations out of the water, as SpaceX has surpassed his predicted 10 tests and done so barely three weeks into the tentative 12-week window he set. SpaceX now has plenty of time to either continue testing Crew Dragon’s parachutes or refocus its efforts on other equally important qualification challenges.

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Prior to those thirteen consecutive successes, SpaceX suffered two failures during single-parachute Mk3 testing. The first two development tests of the Mk 3 design used loads much higher than the parachutes would ever see in operation in an effort to better understand overall design margins and system performance. After a period of rapid iteration with parachute provider Airborne Systems, the faults responsible for those two stress-test failures were resolved and subsequent drop tests confirmed that Mk3’s suspension lines – the numerous lines connecting the parachute to Crew Dragon – are far stronger than those on Mk2.

Perhaps most crucially, the most recent test – shown in the video shared by SpaceX on November 3rd – was the first multi-chute Mk3 demonstration and simultaneously proved that Crew Dragon will be able to safely land its astronaut passengers even if one of the spacecraft’s four parachutes fail to deploy. Despite those consecutive successes, SpaceX and Airborne will continue testing Mk3 parachutes as rapidly as possible and aim to provide NASA the data it needs to qualify Crew Dragon’s parachutes for crewed flight before the end of 2019.

Either way, the next several months are set to be a frenetic period for NASA’s Commercial Crew Program. As early as November 4th, Boeing aims to attempt a pad abort test of its Starliner spacecraft, while SpaceX is set to static fire a Crew Dragon capsule on November 6th. If both tests are successful, SpaceX aims to launch Crew Dragon’s In-Flight Abort (IFA) test in early-December, while Boeing hopes to launch Starliner on its first uncrewed Orbital Flight Test (OFT) no earlier than December 17th.

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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 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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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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Investor's Corner

Tesla uber bull Ron Baron says ‘the time to buy the stock is now’

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Credit: Tesla

In a new interview on Wednesday, Tesla uber bull Ron Baron said that anyone looking to buy the company’s stock should do so as soon as they can.

Baron, founder and CEO of Baron Capital and one of Tesla’s most persistent institutional bulls, used a CNBC Squawk Box appearance on Wednesday to deliver a familiar message with fresh urgency: In his opinion, Tesla stock is a buy:

“The time to buy the stock is now. FSD is catching on, and it’s going to be bigger and bigger. 55% of new buyers are buying it (Teslas) with FSD. It’s going to be everywhere. It’s safer.”

The Baron Capital frontman’s case is built around Full Self-Driving. Tesla reported 1.48 million active FSD subscriptions in the second quarter, up 56 percent year over year, and company officials have said roughly 55 percent of new North American deliveries left with a subscription enabled.

Baron framed that attach rate as proof the product is moving from enthusiast extra to default expectation, and as a reason software, not just vehicle volume, should drive the next phase of value.

His conviction on Tesla shares is not theoretical, as Baron Capital made its first Tesla investment in 2014, after years of meetings that began around the 2010 IPO roadshow. The firm later built a large SpaceX position starting in 2017.

Baron said those Musk-led bets have generated about $30 billion of the $71 billion in profits Baron Capital has produced for clients. He put the firm’s current exposure at roughly $25 billion in SpaceX and $5 billion in Tesla. Personally, he described SpaceX as his largest holding, at about $5 billion, with about $1.5 billion in Tesla and additional Tesla exposure through the firm’s funds.

That concentration is also a statement of loyalty. Asked about talk of a SpaceX-Tesla combination, Baron said he had already walked Elon Musk through arguments for and against a deal, then declined to repeat them on air. His public position was simpler: “Whatever you decide is better is what I’m going to support,” he said to Musk.

Baron also said that he picked up the farewell edition of the Model S after Tesla decided to sunset the vehicle earlier this year, calling it his favorite car he’s ever driven.

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