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SpaceX’s response to Crew Dragon explosion unfairly maligned by head of NASA

SpaceX's first spaceworthy Crew Dragon capsule seen prior to its first Falcon 9-integrated static fire and a post-recovery test fire three months later. (SpaceX)

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In a bizarre turn of events, NASA administrator Jim Bridenstine has offered harsh criticism of SpaceX’s response to Crew Dragon’s April 20th explosion, suffered just prior to a static fire test of its eight Super Draco abort engines.

The problem? The NASA administrator’s criticism explicitly contradicts multiple comments made by other NASA officials, the director of the entire Commercial Crew Program, and SpaceX itself. Lest all three of the above sources were either blatant lies or deeply incorrect, it appears that Bridenstine is – intentionally or accidentally – falsely maligning SpaceX and keeping the criticism entirely focused on just one of the two Commercial Crew partners. The reality is that his initial comments were misinterpreted, but an accurate interpretation is just as unflattering.

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Ultimately, Bridenstine responded to a tweet by Ars Technica’s Eric Berger to correct the record, noting that the criticism was directed at his belief that SpaceX’s “communication with the public was not [good]”, while the company’s post-failure communication with NASA was actually just fine. In fact, according to Commercial Crew Program (CCP) Manager Kathy Lueders, NASA team members were quite literally in the control room during the pre-static fire explosion and the failure investigation began almost instantly.

A blog post and official update published by NASA on May 28th further confirms Lueders’ praise for the immediate SpaceX/NASA response that followed the failure.

“Following the test [failure], NASA and SpaceX immediately executed mishap plans established by the agency and company. SpaceX fully cleared the test site and followed all safety protocols. Early efforts focused on making the site safe, collecting data and developing a timeline of the anomaly, which did not result in any injuries. NASA assisted with the site inspection including the operation of drones and onsite vehicles.”
NASA, May 28th, 2019

Why, then, are Bridenstine’s comments so bizarre and unfair?

A trip down memory lane

Back in mid-2018, Boeing’s Starliner spacecraft suffered a major setback (albeit not as catastrophic as Crew Dragon’s) when a static fire test ended with a valve failing to close, leaking incredibly toxic hydrazine fuel all over the test stand and throughout the service module that was test-fired. The failure reportedly delayed Boeing’s Starliner program months as a newer service module had to replace the contaminated article that was meant to support a critical 2019 pad-abort test preceding Starliner’s first crew launch.

According to anonymous sources that have spoken with reporters like Eric Berger and NASASpaceflight.com, the anomalous test occurred in late-June 2018, followed by no less than 20-30 days of complete silence from both Boeing and NASA. If Boeing told NASA, NASA certainly didn’t breathe a word of that knowledge to – in Bridenstine’s words – “the public (taxpayers)”. Prior to Mr. Berger breaking the news, Boeing ignored at least one private request for comment for several days before the author gave up and published the article, choosing to trust his source.

Boeing’s Starliner spacecraft. (Boeing)

After the article was published, Boeing finally provided an official comment vaguely acknowledging the issue.

“We have been conducting a thorough investigation with assistance from our NASA and industry partners. We are confident we found the cause and are moving forward with corrective action. Flight safety and risk mitigation are why we conduct such rigorous testing, and anomalies are a natural part of any test program.”
— Boeing, July 21st, 2018 (T+~30 days)

SpaceX, for reference, offered an official media statement hours after Crew Dragon capsule C201 suffered a major failure during testing, acknowledging that an “anomaly” had occurred and that SpaceX and NASA were already working closely to investigate the accident. Less than two weeks after that, Vice President of Mission Assurance Hans Koenigsmann spent several minutes discussing Crew Dragon’s failure at a press conference, despite the fact that it was off topic in an event meant for a completely different mission (Cargo Dragon CRS-17).

“Earlier today, SpaceX conducted a series of engine tests on a Crew Dragon test vehicle on our test stand at Landing Zone 1 in Cape Canaveral, Florida. The initial tests completed successfully but the final test resulted in an anomaly on the test stand. Ensuring that our systems meet rigorous safety standards and detecting anomalies like this prior to flight are the main reasons why we test. Our teams are investigating and working closely with our NASA partners.”
— SpaceX, April 20th, 2019 (T+several hours)

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Within ~40 days, NASA published an official update acknowledging Crew Dragon’s accident and the ongoing mishap investigation. Meanwhile, a full year after Starliner’s own major accident, NASA communications have effectively never once acknowledged it, while Boeing has been almost equally resistant to discussing or even acknowledging the problem and the delays it caused. On May 24th, NASA and Boeing announced that Starliner’s service module had passed important propulsion tests (essentially a repeat of the partially failed test in June 2018) – the anomaly that incurred months of delays and required a retest with a new service section was not mentioned once.

During the second attempt, a Starliner service section successfully completed a test that ended in a partial failure during the first attempt ~11 months prior. (Boeing/NASA)

On April 3rd, NASA published a Commercial Crew schedule update that showed Boeing’s orbital Starliner launch debut (Orbital Flight Test, OFT) launching no earlier than August 2019, a delay of 4-5 months. In the article, NASA’s explanation (likely supplied in part by Boeing) bizarrely pointed the finger at ULA and the technicalities of Atlas V launch scheduling.

In other words, NASA somehow managed to completely leave out the fact that Starliner suffered a major failure almost a year prior that likely forced the OFT service section to be redirected to a pad abort test.

Following SpaceX’s anomaly, the company (and NASA, via Kathy Lueders) have been open about the fact that it means the Crew Dragon meant for DM-2 – the first crewed test launch – would have to be redirected to Dragon’s in-flight abort (IFA) test, while the vehicle originally meant to fly the first certified astronaut launch (USCV-1) would be reassigned to DM-2. Thankfully, this practice can be a boon for minimizing delays caused by failures. Oddly, Boeing has not once acknowledged that it was likely forced to do the same thing with Starliner, albeit with the expendable service section instead of the spacecraft’s capsule section.

Again, although the slides of additional CCP presentations from advisory committee meetings have briefly acknowledged Starliner’s failure with vague mentions like “valve design corrective action granted” (Dec. 2018) and “Service Module Hot Fire testing resuming after new valves installed” (May 2019), NASA has yet to acknowledge the Service Module failure and its multi-month schedule impact.

An official slide from NASA Commercial Crew Manager Kathy Lueders, presented in May 2019 – one month after C201’s explosion – during a NASA Advisory Committee (NAC) meeting. (NASA)

So, if SpaceX’s moderately quiet but otherwise excellent communication of Crew Dragon’s explosion was unsatisfactory and worthy of pointed criticism straight from the head of NASA, the fact that Boeing and NASA have scarcely acknowledged a Starliner anomaly that caused months of delays must be downright infuriating, insulting, and utterly unacceptable. And yet… not one mention during Bridenstine’s bizarre criticism of SpaceX’s supposed communication issues.

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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 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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Elon Musk

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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