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SpaceX teases Crew Dragon capsule and spacesuit details in new video

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Over the past few weeks, conference presentations given by SpaceX employees like Joy Dunn and Paul Wooster have kicked off with an updated intro reel including unseen slow-motion footage of Falcon Heavy and detailed looks at the company’s spacesuit and Crew Dragon capsule.

Those in the habit of catching SpaceX launches live will be readily familiar with the company’s intro reel – it’s marked the start of live coverage for nearly every webcast in the past three or more years. The current intro reel has remained more or less unchanged since the first successful Falcon 9 booster recovery in December 2015, and this updated intro reel will be a breath of fresh air for what is still admittedly an amazing video. Still, it’s hard to say “no” to slow-motion footage of Falcon Heavy.

Most recently shown at an MIT Media Lab conference during SpaceX Principal Mars Development Engineer Paul Wooster’s presentation, the new reel has – somewhat unsurprisingly – been built around the incredibly successful inaugural Falcon Heavy launch, as well as some more recent footage of the company’s Cargo Dragon docking with the International Space Station. Additional clips show what appears to be details of the finalized Crew Dragon – set to debut in late 2018 – and a closeup of SpaceX’s internally-designed spacesuit. Sticking out as the only truly unusual snippet, the end of the new reel features parts of the animation SpaceX released in 2016 during the debut of their Mars rocket, the Interplanetary Transport System (ITS), which has since been replaced with the similar but different BFR.

While entirely possible that the inclusion of ITS footage in an intro reel clearly updated since 2018 is intentional, it seems more likely that SpaceX has yet to publicize this new video partially because they don’t yet have a similar animation featuring their updated Mars rocket and spaceship. CEO Elon Musk’s recent comments on the encouraging progress being made with the design and construction of the first BFR prototype suggests that such an updated animation could be just around the corner, if not full-up teaser photos of the construction progress. Set to begin suborbital hop testing as early as the first half of 2019 and orbital launches by end of 2020, SpaceX’s Mars ambitions may still feel far away, but the tech that could make them real is already undergoing preliminary construction and testing.

Sooner still is SpaceX’s upcoming debut of Crew Dragon, the spacecraft that will eventually both carry astronauts to the ISS and later replace Cargo Dragon. Initially intended to land near the launch pad on legs, akin to Falcon 9, SpaceX has since canceled that work, largely due to numerous delays that would have almost certainly been incurred in the process of NASA certification of such a new and unproven technology. Instead, Musk made it clear that SpaceX would instead put its time, energy, and money into the development of BFR and BFS, sidestepping NASA’s sometimes-smothering and counterproductive paternalism for the time being.

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Crew Dragon will instead be recovered after landing in the ocean, a disappointing concession that is at least partially cushioned by SpaceX’s recent successes and growing expertise with the reuse of their similarly sea-recovered Cargo Dragons. While ocean-recovery certainly won’t lend itself to ease of reuse quite as readily as powered landings, SpaceX will likely be able to significantly drop the cost of Crew Dragon launches in the future by efficiently refurbishing each recovered capsule. Less likely but still a possibility, the company could adopt something similar to the fairing-catcher Mr Steven – essentially a giant net aboard a highly-maneuverable boat – to recover Crew Dragon without submerging the spacecraft in saltwater. As of March 2018, at least according to NASA’s Kennedy Space Center director, SpaceX is still on track to conduct its first uncrewed launch of Crew Dragon as early as August 2018, with the first crewed mission following in December 2018 if all goes well.

SpaceX’s spacesuit is a critical component of their crewed spaceflight efforts, and has been designed and built in-house to ensure that astronauts can survive the emergency depressurization of a Crew Dragon capsule, evidenced by Musk’s recent suggestions that senior suit engineers successfully survived stints in a vacuum chamber while wearing it. Thanks to the staggering success of Falcon Heavy and its iconic Starman and Tesla Roadster payload, SpaceX’s spacesuit will undoubtedly be a badge of honor for all future astronauts who fly aboard Crew Dragon.

Starman gives one final farewell to Earth as he departs for deep space aboard Musk’s Tesla Roadster. (SpaceX)

 

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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Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says

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Credit: United Airlines

United Airlines CEO Scott Kirby said that SpaceX’s Starlink satellite internet is its leading competitive advantage in the U.S. airline industry. However, in recent comments, while he described the service as “the biggest competitive advantage” the carrier currently holds, he also acknowledged that the edge is temporary.

“…everybody eventually is going to have high-speed low earth orbit internet connectivity. It’s going to be a must-have. We are going to have a few years of being the only airline that has it at scale, and that’s our mission,” Kirby said. Until everyone has it, United aims to capitalize on its head start by converting trial users into long-term loyal customers.

United has moved faster than its rivals on Starlink installations. As of mid-to-late October 2026, the system was on roughly 43 percent of its fleet, with plans to reach 61 percent by year-end, 87 percent by June 2027, and full fleet coverage by the end of next year.

The airline already operates more Starlink-equipped flights than the rest of the U.S. industry combined. Los Angeles International Airport is scheduled to become United’s first 100 percent Starlink hub in the first half of 2027, and the carrier’s app will display the likelihood that any given flight has the service.

Kirby has pointed to early evidence that the offering influences booking decisions. Some passengers loyal to other airlines are already switching flights for Starlink connectivity, something the airline, along with American Airlines, has tried to leverage against competing airlines. Both companies used status-match programs, and some of those customers are pursuing company-specific credit cards, which signals an intent to stay.

Once onboard, these customers encounter the airline’s broader investments in aircraft, larger seat-back screens, oversized bins, connection tools, and a mobile app that Kirby says outperforms competitors. Wi-Fi satisfaction scores on Starlink-equipped planes have been reported to be nearly double those on aircraft with other systems.

Competitors are moving slowly to do the same. Southwest Airlines began installations in 2025 and expects to complete them soon. Delta is pursuing Amazon’s Leo system, while American expects to start Starlink work in early 2027 and has not yet detailed regional-fleet plans. This timeline gap gives United a multi-year window in which it remains the only major U.S. carrier offering Starlink at scale.

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Kirby has framed the strategy as pressing that advantage while simultaneously widening gaps in other technology areas so that customers who try United for the Wi-Fi remain for the overall experience.

The approach reflects a calculated bet that superior in-flight connectivity can accelerate share gains and support longer-term financial targets, including a 10 percent pre-tax margin goal.

High-speed internet is particularly valued by premium and business travelers who can work or stream reliably. As low-Earth-orbit service becomes ubiquitous, the temporary nature of the pure connectivity edge means United’s retention will depend on whether its other product and operational improvements keep pace.

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Tesla Cybercab’s unorthodox paint process explained

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Credit: Tesla

Tesla Cybercab skips the traditional paint shop entirely, marking an unorthodox process for coloring the fully autonomous vehicle. However, the decision was a smart one, as it slashed factory costs, floor space utilization, and complexity, since Tesla relied on specialized alloys and in-mold coloring.

Munro Live was given the opportunity to do a factory walkthrough with Tesla Vice President of Vehicle Engineering Lars Moravy, who explained and detailed how Cybercab production at Giga Texas eliminates one of the automotive manufacturing industry’s most expensive and space-hungry elements.

A conventional paint line can cost hundreds of millions of dollars and require a million man-hours to build. Moravy framed the choice around Tesla’s core rule: “Question the requirements: why do you need paint?”

The structural answer lies in material selection. The aluminum alloys used in Cybercab’s front and rear castings do not oxidize and lose strength over time, the way many common automotive aluminum alloys do. Only the side modules, built around hot-stamped boron-steel door rings, receive an anti-corrosion e-coat, or dip coat. Front and rear modules skip coating altogether.

Model Y and Model 3 bodies, by contrast, are fully coated and painted.

Exterior colors come from the plastics shop, which Tesla engineers described as “our paint shop” for the Cybercab. Body panels are produced via reaction injection molding, referred to as RIM. Color is then mixed into a polyurethane resin at the mix head immediately before injection, so the panel emerges already colored with a Class-A surface.

Robots trim overflow to control sink marks and flow lines. The process avoids conventional spray-paint defects like orange peel and paint bleed. Scratches can still be repaired with compatible coatings that behave “basically like paint.” Because color is integral rather than a surface layer, shallow scratches do not expose a contrasting undercoat.

The secret behind Tesla’s Cybercab Gold goes well beyond just the color

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Tesla has also explored related approaches, including in-mold lamination and painted films on stamped panels.

The manufacturing payoff is substantial because removing the paint shop, combined with the “unboxed” modular process that builds and tests front, rear, side, and center modules in parallel before a short final assembly, cuts factory floor space per vehicle by about 50 percent.

Final assembly itself uses only about 25 automated stations, far fewer than the typical Model Y line, and the overall line runs at about 78 percent automation, Moravy said. The approach also eliminates volatile organic compound emissions associated with traditional spray painting for these panels and shortens the coloring cycle from hours to minutes.

Cybercab’s paint strategy is clearly less about aesthetics than about systematically deleting capital-intensive, energy-heavy, and space-consuming steps once material science and process design make them unnecessary. It is a concrete example of Tesla applying first-principles questioning to one of the auto industry’s most entrenched factory requirements.

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Tesla has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

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Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

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The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

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