News
SpaceX gears up for Crew Dragon’s first recovery with a giant inflatable cushion
Paired with observations and comments from sources familiar with the company, all signs seem to indicate that SpaceX is planning to recover their first Crew Dragon spacecraft with a giant inflatable cushion, to be towed a hundred or so miles off the coast of California by one of the company’s Port of LA-stationed recovery vessels.
Despite a minor mishap during some sort of inaugural sea-trial of a custom Crew Dragon mass simulator, SpaceX technicians are pushing ahead with a test campaign intended properly characterize exactly how to best recover a Dragon while side-stepping around the problems caused by seawater immersion.
Inside the clean room at SpaceX HQ, Crew Dragon is nearing completion. This will be the capsule to make the first crewed flight, currently slated for April 2019.#spacex #CrewDragon @Teslarati pic.twitter.com/tjzuwfGV2O
— Pauline Acalin (@w00ki33) August 16, 2018
Why recover your Dragon?
First off, why would SpaceX choose to develop a new method of Dragon recovery – different than the company’s current experience with simply landing the capsules in the ocean – with the expectation that it will debut during the recovery of Crew Dragon after its very first demonstration mission (DM-1)? A huge number of unknowns and major questions remain, but the decision to attempt to avoid seawater immersion during the DM-1 Dragon recovery is very likely no coincidence.
Over the last several years, SpaceX engineers and technicians have learned a huge amount from recovering, refurbishing, and even reusing Cargo Dragons to resupply the International Space Station for NASA. Of all the lessons learned, the most unequivocal has to be a newfound appreciation for just how difficult it is to safely and reliably reuse spacecraft and rocket components after landing and being immersed in seawater. Despite SpaceX’s growing experience with reusing both Falcon 9 and Cargo Dragon, Dragons still typically require a bare minimum of 6-12 months of refurbishment before they are ready for another launch.
- SpaceX’s CRS-13 Cargo Dragon, capsule C108, seen near the end of its refurbishment. (SpaceX)
- A reused orbital spacecraft, Cargo Dragon, back on Earth after its second successful resupply mission. (SpaceX)
- All Crew and Cargo Dragons are built and refurbished in the same processing facility, a clean-room inside SpaceX’s Hawthorne, CA factory. (SpaceX)
For Crew Dragon’s DM-1 debut, it thus makes sense that SpaceX wants to recover the spacecraft in such a way that it is exceptionally easy to rapidly refurbish. Perhaps just several months after that capsule returns to Earth, currently expected no earlier than December 2018, SpaceX’s first crewed Crew Dragon demonstration’s tentative April 2019 launch debut will depend entirely on the completion and review of an In-Flight Abort (IFA) test planned just one month prior, March 2019.
The planned IFA test of Crew Dragon hinges entirely on DM-1 and Dragon refurbishment because the present plan (and launch schedule) absolutely depends on reflying DM-1’s Crew Dragon capsule, potentially recovered from orbit as few as three months prior.

With a successful 2015 Pad Abort already under Crew Dragon’s belt, SpaceX voluntarily chose to conduct an additional complimentary in-flight abort not explicitly required by NASA, designed to demonstrate that Dragon will be able to safely extract astronauts from a failing rocket at the point of peak aerodynamic pressure (Max-Q). Essentially, a combination of successful aborts both on the launch pad and during Max-Q would theoretically demonstrate beyond any reasonable doubt that Crew Dragon really is capable of safely aborting a launch and protecting its astronauts at any point during launch.
Cargo Dragon has demonstrated that – apparently – no amount of heroics can refurbish the recovered spacecraft in just a small handful of months after seawater immersion, not without major changes to its design. As such, preventing that with some sort of inflatable cushion (or even Mr Steven’s net) would likely save many months of drying, cleaning, and requalification testing of all externally impacted components.
- Cargo Dragon returns to Earth looking rather well-done. (SpaceX)
- The first spaceworthy Crew Dragon capsule is already in Florida, preparing for its November 2018 launch debut. The same capsule will be refurbished and reflown as few as three months after recovery. (SpaceX)
- SpaceX Crew Dragon capsule C203 – then assigned DM-2 – is seen here in August 2018. (Pauline Acalin)
How to recover your Dragon
While the “why” is fairly obvious at this point, the “how” of actually making such a cushioned recovery happen is far less clear. Still, we at least know from several recent comments from SpaceX CEO Elon Musk and statements made in environmental impact analyses that the company has been considering such recoveries for some time.
Despite the fact that Crew Dragon’s original propulsive landing capability was nixed due to the unlikelihood of NASA ever certifying it for crewed landings and the expense required to attempt that certification, there is still clearly some latent interest (and value) in precisely landing Crew Dragon, even if only to speed up capsule and crew recovery after splashdown. A March 2018 preliminary environmental impact analysis of Gulf of Mexico Dragon recoveries – as a backup to bad weather in the Pacific and Atlantic – made the interest in precision exceptionally clear.
“The splashdown zone is a circle with a radius of approximately 5.4 nautical miles. … Dragon has been designed to perform precision landings in order to minimize the size of the splashdown zone and recovery time.”
Admittedly, a circle with a diameter of 10.8 nautical miles (20 km) does not exactly scream “precision” and ~20 km is likely around a thousand times less precise than what’s needed to land on the 30m-diameter inflatable structure present at Berth 240, but it’s probable that the splashdown zone as discussed is a worst-case scenario meant to give SpaceX’s recovery team plenty of wiggle room.
- Crew Dragon was originally designed with propulsive landings in mind, much like Falcon 9’s booster recovery. (SpaceX)
- In place of propulsive landing, it appears that a giant inflatable cushion is the new solution for quick reuse. (Pauline Acalin)
Musk also took a few seconds of a Falcon Heavy post-launch press conference to briefly describe Mr Steven, and he just so happened to touch on fairing and Dragon recovery:
“And we’ve got a special boat to catch the fairing. … It’s like a giant catcher’s mitt in boat form. I think we might be able to do the same thing with Dragon. So…if NASA wants us to, we can try to catch Dragon. Literally, it’s meant for the fairing, but it would work for Dragon, too.” – Elon Musk
Mr Steven takes one for the team
Even more experimental than fairing recovery, SpaceX happened to experience a minor incident while attempting to test aspects of its prototype Dragon catcher apparatus in early August. Partially captured by Teslarati photographer Pauline Acalin, SpaceX technicians were lifting a Crew Dragon heatshield mass simulator with a healthy topping of buoys onto Mr Steven. Moments after it was lowered onto the deck, the whole setup disappeared below the vessel’s side rails in a massive boom.
- The Crew Dragon mass simulator is loaded onto Mr Steven for the first time, August 3rd. (Pauline Acalin)
- Shortly after touchdown, the mass sim disappeared with a deafening boom, presumably breaking through Mr Steven’s wooden deck. (Pauline Acalin)
- SpaceX technicians lift a Crew Dragon mass simulator off of Mr Steven’s deck after accidentally breaking it. (Pauline Acalin)
According to sources familiar with SpaceX’s recovery fleet, the mishap was much less severe than the deafening noise it produced seemed to indicate from the sidelines. They described the aftermath as “an annoying accident” that was unlikely to take any significant amount of time to repair. More likely than not, Mr Steven’s wooden deck suffered some level of structural degradation after several years of active use, something that SpaceX technicians only discovered after loading (or maybe dropping) a heavy Dragon mass simulator aboard.
Regardless, one could certainly say that the test in question was more or less a success, as it most certainly demonstrated whether Mr Steven’s deck was actually capable of supporting the heavy test article (it was not). A few repairs and structural reinforcements later, the vessel is likely already back in working order, with photos taken on August 19th showing that the focus has returned to the vessel’s arms (two of which must have been removed earlier this week).

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Investor's Corner
Tesla Optimus Gen 3 shows off a cleaner, factory-ready design in new app discovery
Renders hidden inside Tesla’s Android app show Optimus Gen 3’s design before any official reveal.
Tesla may have accidentally given a first look at its newest Optimus Gen 3 humanoid robot when photos were found in the Tesla smartphone app.
Design files tucked inside a recent Android version of the Tesla app appear to show the third generation humanoid robot next to the older Gen 2.5 prototype. The assets were extracted from the app package by Tesla community member @wholemars, who posted the renders on X late Tuesday night before deleting them. The Tesla Newswire reshared the side by side comparison on Wednesday, and the images have circulated widely since.

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X
The files are labeled “gen3” and were built as models for Tesla app’s own interface, as validated directly by Grok to be official.
The comparison shows a robot that looks built for a factory line rather than a lab bench. Gen 2.5’s exposed mechanical linkages and gold plating on the knees and shins are gone. In their place, Gen 3 uses matte black fairings on the lower legs, paired with a more contoured champagne gold body. Flexible covers now seal the joint where the torso meets the upper thighs, keeping bearings and moving parts sealed from debris and unnecessary contact.
The body panels fit more tightly, and the hands, which Tesla has said carry 22 degrees of freedom, look far more refined than those on earlier units.
This most recent leak fills a gap Tesla has left open for most of the year. Elon Musk said on March 31 that Optimus 3 was walking around but needed “some finishing touches” before it could be shown, a delay Teslarati covered when Tesla missed its first quarter reveal target. Musk later said Tesla would hold the design back until closer to production, partly to keep competitors from copying it. No reveal date has been announced.
The app itself has been preparing for Optimus for months. In July, code in the Tesla app pointed to a dedicated robot phone key, a consent screen for collecting video and spatial data while Optimus works inside a home, and an alert system for low battery and mechanical faults. Finished 3D models of Gen 3 suggest the interface owners will eventually use is moving past placeholder code toward something Tesla intends to ship.
Manufacturing is moving in parallel. Tesla tore out the original Model S and Model X lines at Fremont this summer to make room for Optimus production, with a planned capacity of one million robots a year. At Giga Texas, the steel frame of a dedicated Optimus factory is nearing completion ahead of a targeted 2027 start, with Musk pointing to an eventual output of 10 million units annually.
News
Tesla Semi lands the biggest electric truck deal in U.S. history
Tesla leads a record 2,500 truck order, but not every truck will be a Semi.
Tesla has landed the largest electric truck order in U.S. history. ZET SCALE, a new alliance of shippers and carriers, named Tesla its primary manufacturer on Tuesday for an initial order of 2,500 electric Class 8 trucks. The deal alone would nearly double the number of electric heavy trucks operating in the country.
According to the press release from Catalyst Mobility, the nonprofit formerly known as CALSTART, Kenworth, RIDE and Volvo were also selected as secondary manufacturers that carriers can pick if their operations call for it. No split between the four brands has been published, so the exact number of Semis in the order is not yet known.
Tesla was selected as the primary OEM for the largest electric Class 8 order in the US by ZET SCALE, a new shippers’ alliance
With 2,500 Semis on order, this will double the entire US electric Class 8 fleet
We’re serious about scale, and ZET SCALE is too!… pic.twitter.com/IiTAdzgken
— Tesla Semi (@tesla_semi) September 22, 2026
Tesla won the top slot through a competitive request for proposals. The alliance, which Catalyst Mobility runs with the Smart Freight Centre, scored bidders on price, range, charging capability and production capacity. Pooling freight demand from founding shippers, including Microsoft and PepsiCo, let every truck maker bid lower than it would for a single fleet. “The Tesla Semi is designed for lower cost per mile operations than diesel,” said Dan Priestley, director of the Tesla Semi program, as noted in the press release.
The financing is built to pull in carriers who have avoided electric trucks. ZET Financial is issuing the purchase order for all 2,500 units and will place them with fleets through a fair market value lease. The trucks will be deployed over the next few years across 10 freight hubs in Los Angeles, Stockton, Bakersfield, Seattle and Tacoma, Houston, Dallas, San Antonio, Chicago, Atlanta, and the Newark and New York area. ZET SCALE says the first order is only the opening round, with a longer term goal of 10,000 trucks or more.
Even if Tesla ends up with only a majority share, it would still be the biggest Semi deal to date. Einride’s 500 unit order in August was the previous record, and WattEV’s 370 truck order in May was the largest California deal at the time. Einride’s CEO has since said he expects all 500 trucks delivered by the end of 2027.
The announcement lands two days before Tesla formally inaugurates its Semi factory in Nevada on September 24. The 1.7 million square foot plant sits next to Gigafactory Nevada’s 4680 cell lines and is designed for 50,000 trucks a year.
News
Tesla integrates Grok Bot into its vehicles for the ultimate personal assistant
Tesla has expanded Grok from an in-car chatbot into a hands-free work assistant. On September 22, Tesla officially launched Grok Bot capability, confirming that drivers can now manage email, calendars, files, chats, and tasks by voice and then hand more ambitious errands to the AI-fueled productivity cheat code.
Grok itself is built by xAI. The new car features split into two layers: Connectors link Grok to outside accounts. Grok Bot, currently limited to SuperGrok Heavy subscribers, can complete multi-step tasks such as placing a usual coffee order, booking a reservation, or scheduling an appointment. It truly puts the driver in a nearly complete hands-free driving and productivity setting, with ironically the only task truly requiring your hands being to touch the “Start Self-Driving” button.
We were granted access to Grok Bot’s Tesla integration a few weeks back, and we’ve been able to do a handful of things with it. On a handful of occasions, we’ve used it to order food and have it ready for pickup slightly later into the evening; we’ve managed to pick up groceries after a day of errands with Grok Bot, and outside of the car, it’s helped with budgeting and even my fantasy football draft.
We’ve been using @Grok Bot in Tesla for a few weeks after gaining Early Access, which we thank the awesome engineers for
Grok Bot makes things much easier across your entire life. From the Tesla, I’ve used it to place pickup orders for my Fiancée and I, we’ve ordered groceries… https://t.co/ZJSLieG1s5
— TESLARATI (@Teslarati) September 22, 2026
Tesla shows another way to utilize it: in their demo, a driver says “Hey Grok,” asks the assistant to check an inbox, and hears that a message concerns a weekend reservation. Grok then scans the calendar, reports no conflicts, and confirms the Tahoe trip is clear. It can also add check-in details to a road-trip itinerary. The point is not novelty chat. It is keeping eyes on the road, or on Full Self-Driving, while the car handles the paperwork of a trip:
.@Grok in your Tesla can now do meaningful work for you
With Connectors, you can manage your inbox, clean up your calendar, or talk through existing files/chat/tasks – all hands-free pic.twitter.com/W1LuybQh0P
— Tesla (@Tesla) September 22, 2026
This Grok rollout is not a gadget add-on as much as it is Tesla’s thesis in software form: the car should stop being a machine you operate and start being a room you occupy.
Connectors and Grok Bot treat the cabin as an office that happens to move, and that has truly been Tesla’s intention for years now. The car has slowly become an extension of a home more than a vehicle. Inbox, calendar, groceries, takeout, and reservations become voice work, not dashboard chores that you need to do before you get in your car.
Responsibility shifts from the driver to the stack, and as many Tesla owners rely on FSD for travel, Grok Bot now handles the monotony of dinner reservations or appointments.










