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SpaceX Crew Dragon spacecraft sails home after flawless in-flight abort test
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.
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.
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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Elon Musk
SpaceX turned a heralding moment for Starship into its greatest moment
Starship reached orbit despite losing an engine, deployed 26 Starlink V3 satellites on Flight 14.
SpaceX’s Starship reached orbit for the first time on Monday, and for a few nail-biting minutes it looked like it wouldn’t. During ascent on Flight 14, one of Ship 41’s six Raptor engines shut down early, and SpaceX’s livestream host Dan Huot told viewers the team had decided not to commit to orbit. Minutes later, after what Huot described as a lot of conversation in the control room, the final poll came back in favor, and a roughly 19 second burn of a single Raptor pushed the ship into orbit about 170 miles up.
The reversal matters because SpaceX had written the exit ramp into the mission plan. The company said it would only fire the orbital insertion burn if flight controllers confirmed enough backup hardware remained for the deorbit burn, a condition Teslarati laid out ahead of the flight. Losing an engine was exactly the scenario that rule was built for.
Pressing forward fits Elon Musk’s history. Falcon 1 failed three straight times before its fourth launch reached orbit in 2008, with SpaceX nearly out of money, and Starship was developed by flying prototypes until they broke. What changed this year SpaceX going public, and with $SPCX sliding below its IPO price in July when Flight 13 slipped, the short interest climbed significantly, as Teslarati reported at the time. A Starship potentially lost today with revenue generating next-gen Starlink satellites aboard would have landed directly on shareholders.
Splashdown confirmed. Congratulations to the entire SpaceX team on the first orbital flight of Starship! pic.twitter.com/urjmiwnvNl
— SpaceX (@SpaceX) September 28, 2026
That pressure showed up after orbit. SpaceX cut a flight planned to last nearly 10 hours to about three, moving splashdown from west of Chile to the North Pacific near Hawaii. SpaceX gave no reason, though Musk said this month the company was being extremely cautious about debris risk. The single Raptor for deorbit worked, and Ship 41 completed its flip and landing burn before breaking apart in the water, an outcome SpaceX expected. Musk has structured SpaceX’s governance to shield long term bets from market pressure.
The payload is the bigger business story. Musk posted that all 26 Starlink V3 satellites deployed and are “operating nominally.” Each V3 is rated for about 1 Tbps of downlink and 160 Gbps of uplink, so this single launch adds roughly 26 Tbps, about 10 times what a Falcon 9 load of V2 Mini satellites adds. The V3 is too large for Falcon 9, making Starship the only vehicle that can build out the planned 100,000 satellite constellation, at up to 60 per flight once it reaches routine service. Unlike the 20 V3 units on Flight 13, which reentered on a suborbital path, these will raise their orbits and could begin serving customers within weeks and bring in hundreds of millions of additional dollars in projected Starlink revenue.
SpaceX has already begun winding down Falcon 9 Starlink launches from Florida in favor of Starship. Reported targets put Flight 15 as early as October 19, leaving about three weeks to diagnose Monday’s engine shutdown before the next orbital attempt.
Starship’s 14th flight is set to launch on Monday, Sept 28. The 75-minute launch window opens at 7:15 a.m. CT. Live coverage of the mission starts ~35 minutes before launch → https://t.co/uQKQvgaTmJ
— SpaceX (@SpaceX) September 27, 2026
Tesla quietly doubled the size of its Cybercab fleet within the Robotaxi program in Austin, Texas, over the weekend to well over 100 units.
The move not only establishes more of the steering-wheel-less and pedal-less vehicles within the ride-sharing fleet Tesla has been operating for a year, but it also solidifies a more robust Robotaxi fleet as a whole.
Riders started receiving notifications from the Robotaxi app that stated: “Cybercab fleet has doubled: more rides available.”
I got this notification on the robotaxi app. They are saying the Cybercab fleet has doubled. Glad that they are advertising this pic.twitter.com/FFrnw4FRCF
— Abhimanyu Yadav (@WorldlyReviewer) September 26, 2026
Tesla first launched rides in the Cybercab in early September, although the Robotaxi fleet has been active for over a year, as rides began last Summer. Cybercab is truly Tesla’s most crucial vehicle release yet, as it is the first car any company has built that is geared toward full-fledged and end-to-end autonomy, never needing human intervention for anything.
Only available in Austin at the current time, Cybercab has two seats and has been spotted testing around various U.S. states and regions; Tesla plans to deploy the Cybercab in various U.S. cities in the coming months as a best-case scenario.
Tesla Cybercab gets initial tie-in to localized, in-house cathode plant
The availability of the Cybercab has doubled from just 58 units last Monday to 125 the following Friday. Marking a substantial increase in Cybercab availability, the additional ride-sharing units are more than welcome, as wait times for Cybercabs, especially, were quite high.
The dramatic increase is a sign that demand for Robotaxi is growing and Tesla is feeling more confident that its driverless ride-hailing suite, especially its Full Self-Driving software, is able to handle any traffic situation without explicit direction or supervision from a human being.
Tesla is advancing a fully automated pipeline for the 4680 battery cells used in its all-electric Semi, spanning production from Giga Texas through shipment and direct consumption on the line at the new dedicated Semi Factory in Sparks, Nevada.
The approach was outlined by Tesla at its September 24 Semi Handover event, which launched high-volume production at its new 1.8-million-square-foot plant in Nevada, which sits adjacent to Gigafactory Nevada and is designed for an annual production rate of 50,000 trucks per year.
After years of pilot builds and what was a four-year-long redesign of the truck, Tesla moved the Semi from 2170 batteries to its in-house 4680 cells, which are made in Austin. The change cuts battery mass and total energy while holding range, a key step in making volume production a realistic possibility.
Cells will leave Giga Texas in trailers, and at the Nevada Semi plant, Tesla intends for a dedicated line to unload those trailers automatically, station the cells, and feed them straight into pack and vehicle assembly.
🚨 Tesla plans to use a completely automated unloading process for cells coming from Giga Texas arriving at the Semi factory in Nevada
A line will “consume” cells from the trailer
The goal is to have zero human touch point throughout the entire process. Insane! pic.twitter.com/wdBFM8LC3F
— TESLARATI (@Teslarati) September 25, 2026
Both Lars Moravy, Tesla’s VP of Vehicle Engineering, and Dan Priestley, the Head of Tesla’s Semi program, described the goal as a “zero human touch point” from the moment the trailer arrives in Texas until a finished Semi drives off the production line in Nevada.
The unloading system that Moravy and Priestley described is just one piece of a much broader automation push. The plant uses what Tesla calls the highest-capacity electric monorail conveyance in vehicle manufacturing, carrying frames-in-white simultaneously. Powder-coating replaces conventional paint, and many processes that would normally require operators have been designed out.
Tesla has repeatedly said that “the best part is no part,” and the cell-handling plan extends that philosophy from the cell factory floor in Texas all the way to final assembly in Nevada.
If executed as described, the closed-loop flow would reduce labor, handling damage, and inventory buffers while tightening quality control on a component that represents a large share of the truck’s cost and weight. It also shortens the physical and organizational distance between two factories separated by more than 1,200 miles. The Semi itself now shares a bar-wound stator and other components with the Cybertruck, further linking Tesla’s passenger and commercial production systems.
High-volume output is expected to ramp gradually after the first trucks left the new line in April 2026. Early customers include PepsiCo, DHL, and U.S. Foods. Whether the automated trailer-to-line process reaches the promised zero-touch standard will be visible in the coming months as production scales. For Tesla, the Semi factory is another test of how far it can push “the machine that builds the machine” across sites.
SpaceX turned a heralding moment for Starship into its greatest moment
Tesla Cybercab fleet doubles to well over 100 units
