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NASA says that a minor accident that destroyed a crucial Crew Dragon mockup on March 24th should have minimal impact on the spacecraft's astronaut launch debut. (Richard Angle) NASA says that a minor accident that destroyed a crucial Crew Dragon mockup on March 24th should have minimal impact on the spacecraft's astronaut launch debut. (Richard Angle)

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SpaceX's Crew Dragon is about to escape a supersonic rocket: here's how to watch live

SpaceX's Crew Dragon spacecraft is ready for its second launch ever on a Falcon 9 rocket but this mission's destination is far from orbit. (Richard Angle)

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SpaceX’s Crew Dragon spacecraft is set to attempt to escape a supersonic Falcon 9 in what will likely be the first intentional in-flight destruction of an orbital-class rocket in decades.

Known as an In-Flight Abort test, Crew Dragon’s second test flight is guaranteed to be spectacular and will thankfully be streamed live by both NASA and SpaceX. Scheduled to lift off no earlier than 8 am EST (13:00 UTC), January 18th, the IFA could also be Crew Dragon’s last uncrewed launch ever, hopefully paving the way for its first orbital flight with NASA astronauts on board just a few months from now.

For now, SpaceX’s primary focus with the IFA test is to prove that Crew Dragon can protect passengers and cargo even in the unlikely event that Falcon 9 fails in flight – after liftoff but before the spacecraft has separated from the rocket.

After several months of delays brought on by the explosion of Crew Dragon capsule C201 in April 2019 and an additional two-week slip from NASA’s first public launch date, Falcon 9 booster (B1046) and Crew Dragon capsule C205 have both completed static fire tests of their respective rocket engines and rolled out to Pad 39A on January 16th.

After at least half a year of investigation and a similar period spent redesigning and requalifying a subsection of the high-pressure propellant plumbing that feeds Crew Dragon’s SuperDraco abort thrusters, new capsule C205 successfully fired up a handful of Draco maneuvering thrusters and all 8 of its SuperDracos abort engines, simulating the burns it will have to perform during Saturday’s IFA test.

A pair of Crew Dragon’s upgraded SuperDraco abort engines perform a static fire test. (SpaceX)

According to NASA and SpaceX, the ~48 hours between rollout and liftoff have been used to perform a dry run for future NASA astronaut launches, more or less exactly replicating the processes that will soon be used for real. Of course, Demo-2 astronauts Bob Behnken and Doug Hurley didn’t actually board the Crew Dragon spacecraft (its interior is unfinished) and will certainly not be on board come liftoff, but everything up to the point of spacecraft ingress was performed as if they will be.

https://twitter.com/JimBridenstine/status/1218244543209852928

Audiences will likely be treated to a rare view from inside SpaceX’s flight operations center, recently permanently relocated to Firing Room 4 of NASA’s Flight Control Center (FCC) – a facility with substantial historical ties to US human spaceflight. It was last utilized as part of Crew Dragon’s inaugural orbital launch – “Demo-1” – in March 2019.

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A view of Firing Room 4 in NASA’s Flight Control Center used during Crew Dragon’s inaugural Demonstration-1 Mission in March of 2019.

Approximately 90 seconds after liftoff, shortly after a point of maximum aerodynamic stress called Max Q, Crew Dragon will ignite its SuperDraco abort thrusters in an attempt to prove that it can whisk astronauts to safety in even a near-worst-case scenario. After a 10-second SuperDraco burn, the spacecraft will have to stabilize itself, reenter the bulk of Earth’s atmosphere, and deploy four main parachutes for a gentle splashdown in the Atlantic Ocean.

A combined SpaceX and USAF team will recover the hopefully-intact spacecraft from the ocean, likely using the opportunity to once again simulate the process of recovering a crewed Crew Dragon and safely extracting the NASA astronauts strapped inside it.

SpaceX’s Crew Dragon is guided by four parachutes as it splashes down in the Atlantic Ocean about 200 miles off Florida’s east coast on March 8, 2019, after returning from the International Space Station on the Demo-1 mission. (NASA)

Falcon 9 booster B1046 is expected to be “destroyed in Dragon fire”, according to SpaceX CEO Elon Musk. The Crew Dragon capsule will jettison mid-flight, leaving B1046 open to extremely abnormal aerodynamic stress that will likely tear it and the upper stage apart. NASA says SpaceX will attempt to recover as much of the expected rocket debris as possible.

Crew Dragon’s IFA test has a four-hour launch window with liftoff targeted no earlier than (NET) 8 am EST (13:00 UTC), January 18th. For a variety of reasons, this mission is uniquely susceptible to weather both at and around the launch pad and stands a good chance of slipping much later into the window, and backups are available at the same time on Sunday and Monday.

Regardless, SpaceX will provide live coverage of the test whenever it does launch, beginning around 15 minutes prior to liftoff. Teslarati photographer Richard Angle and reporter Jamie Groh will be on-site to document the events of Crew Dragon crucial – and likely spectacular – flight test.

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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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Investor's Corner

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Investor's Corner

Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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