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SpaceX Crew Dragon spacecraft sails home after flawless in-flight abort test

Pictured here, Crew Dragon C201 returned to Port Canaveral on March 10th, 2019. After completing a flawless in-flight abort test, Crew Dragon C205 has itself returned to port on January 19th, 2020. (Teslarati)

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SpaceX’s newest Crew Dragon spacecraft has successfully returned to port aboard one of the company’s dedicated recovery vessels, neatly wrapping up what appears to have been a completely flawless in-flight abort (IFA) test.

Designed to prove that Crew Dragon can safely escape a failing Falcon 9 rocket at essentially any point from the launch pad to orbit, SpaceX voluntarily chose to perform a full-fidelity IFA test – something NASA left up to both it and Boeing. Boeing instead decided to extrapolate from a pad abort test – which SpaceX completed in 2015 – and a presumably large number of digital simulations to verify that Starliner would survive an in-flight abort.

To be clear, NASA is explicitly okay with this, but space agency officials did not shy away from openly embracing the superiority of integrated flight testing at several points both before, during, and after SpaceX’s second Crew Dragon launch. Although it will almost certainly remain (publicly) unsaid, there should be little doubt that for astronauts scheduled to fly on either Crew Dragon and Starliner, the successful completion of in-flight abort and pad abort tests almost certainly engenders at least a little more confidence in the vehicle they will be entrusting their lives to.

It’s worth noting that although NASA argues – perhaps soundly – that digital modeling, a pad abort test, and an orbital flight test are enough to determine whether any given spacecraft is safe enough to launch US astronauts, the unspoken reality – or at least a large part of it – is that cost is a major concern. At this point in time, NASA’s Commercial Crew Program (CCP) contracts are expected to cost a total of $3.1B for SpaceX and $5.1B for Boeing – both including at least four total orbital launches of their respective spacecraft.

In simpler terms, despite the fact that SpaceX has received a full $2 billion (~40%) less than Boeing to accomplish the same tasks in the same time, SpaceX’s Crew Dragon completed a flawless orbital launch debut and space station rendezvous with Crew Dragon almost 10 months before Boeing’s Starliner suffered a serious partial failure in space. Simultaneously, for $2 billion less, SpaceX has now given NASA a seemingly flawless full-up in-flight abort test of Crew Dragon before the space agency will fully entrust the spacecraft with the safety of its astronauts.

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In the last 10 or so weeks, Boeing has thus suffered a minor Starliner parachute failure, a far more concerning spacecraft failure during its first orbital flight test (OFT), has no plans to perform an in-flight abort test, and nevertheless still wants Starliner’s next launch to carry NASA astronauts.

A clear path ahead

SpaceX, on the other hand, has now completed two seemingly-flawless integrated launches of Crew Dragon on a Falcon 9 rocket – one of which successfully rendezvoused with the ISS and returned to Earth; the other of which has now proven that Crew Dragon can whisk astronauts to safety from a failing supersonic rocket. SpaceX says it will carefully inspect capsule C205 and eventually refurbish the spacecraft, although it’s entirely unclear what kind of mission the company could foreseeably reuse it on in the near future.

Crew Dragon lifts off for the first time on Demo-1, March 2019. (Pauline Acalin)
With its successful In-Flight Abort test, Crew Dragon has now performed two flawless launches on Falcon 9 rockets. (Richard Angle)

Speaking shortly after Crew Dragon’s second flawless launch, SpaceX CEO Elon Musk said that he had spoken with NASA administrator Jim Bridenstine just prior to the post-launch press conference and together came up with a response to the most obvious question: when will SpaceX fly astronauts? In short, Musk was almost certain that all the hardware needed for the Demo-2 astronaut test flight – Falcon 9 booster, F9 upper stage, Crew Dragon capsule C206, and a Dragon trunk – will be completed, tested, and delivered to Cape Canaveral by late-February 2020.

If everything goes exactly as planned, NASA – prior to launch – indicated that an early-March 2020 launch was actually within reach. After launch, Musk tempered expectations, stating that SpaceX would almost certainly launch its first NASA astronauts sometime in Q2 – perhaps as early as April. Regardless, it looks like we wont have to wait more than a few months to find out.

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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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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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