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SpaceX readies for astronaut capsule recovery backup plan as rocket drone ship deploys to landing zone

The SpaceX autonomous spaceport drone ship Of Course I Still Love You returns empty to Port Canaveral following a Starlink mission missed landing attempt. (Credit: Richard Angle for Teslarati)

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Mission objectives of the SpaceX Crew Dragon Demo-2 test flight, have already commenced days ahead of the scheduled launch attempt. On Wednesday, May 27th at 4:33 pm EDT, Elon Musk’s rocket launching – and landing – company, SpaceX, will set out to achieve more firsts than it has ever attempted in one launch. The final Crew Dragon test flight will shuttle NASA astronauts Bob Behnken and Doug Hurley to the International Space Station for the very first time. Along with the primary mission objective to deliver the astronauts safely, many secondary objectives are built into the mission profile. One of which is autonomously turning the Falcon 9 booster around shortly after launch to land on a floating barge in the middle of the Atlantic Ocean.

During the late hours of Saturday, May 23rd, a trusted veteran member of the SpaceX fleet of recovery vessels, Tug Hawk, returned to Port Canaveral to transport SpaceX’s autonomous spaceport drone ship, Of Course I Still Love You (OCISLY) to the designated booster recovery zone some 510km downrange. It seems that Tug Hawk and its crew returned specifically to assist with the recovery efforts of SpaceX’s highest-profile launch to date as there was already another tug at Port Canaveral available to assist that was not used. The arrival was captured by long-time port activity documenter, Julia Bergeron, and reported by the unofficial Twitter SpaceX recovery vessel tracking account, SpaceXFleet.

The SpaceX recovery fleet portion of the Demo-2 mission got underway on the morning of Sunday (May 24th). Space Coast local Greg Scott was at Port Canaveral to capture Tug Hawk’s departure with OCISLY in tow just twelve hours after arriving. About an hour later, the OCISLY support vessel that carries cargo and crew essential for booster recovery efforts, GO Quest, departed. It will take Tug Hawk and OCISLY approximately two days to travel to the recovery zone, arriving about 24 hours before the launch attempt.

The propulsive landing of a booster at sea is not a new concept for SpaceX. However, it is a practice that can be somewhat tricky to get right every time due to a multitude of factors. Recently, SpaceX suffered the loss of the Falcon 9 boosters B1056 and B1048 following recent Starlink satellite launches. Both boosters suffered unrelated issues with high winds and software glitches resulting in failed attempts to stick the landing on OCISLY. However, SpaceX successfully demonstrated the reliability of the Falcon 9 landing capability with the flawless launch and landing of the April 22nd Starlink Falcon 9 B1051 booster.

A special circumstance of the Demo-2 mission is the added recovery requirements of the Crew Dragon capsule. With Crew Dragon launching from LC-39A at the Kennedy Space Center in Florida and splashdown designated for the Atlantic Ocean, various recovery zones span almost the entire length of the United States’ eastern seaboard and across the Atlantic Ocean to Ireland. Special recovery zones also are located throughout the Gulf of Mexico.

Typically, the recovery of a crew capsule would only be thought to occur upon mission end when it is on approach for splashdown after re-entry. However, the specially equipped SpaceX Crew Dragon recovery vessels, GO Searcher and GO Navigator, are required to be able to respond to a number of locations during launch and through the entire duration of Crew Dragon’s time on orbit chasing down the International Space Station prior to docking – for Demo-2 that will be nineteen hours. This is to ensure that in the unlikely event of Crew Dragon experiencing an emergency pad or launch abort scenario, the crew aboard can be safely rescued.

To this end, GO Searcher departed Port Canaveral days ago destined for the Naval Air Station in Pensacola on Florida’s west coast. GO Navigator will remain at Port Canaveral until Crew Dragon returns for a splashdown following the conclusion of Demo-2. Dual Dragon recovery vessels stationed on either side of Florida ensures that Hurley and Behnken can be rescued should they require emergency recovery.

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Should Demo-2 pass SpaceX’s upcoming final Launch Readiness Review scheduled for Monday, May 25th, all will proceed toward the launch attempt on Wednesday, May 27th at 4:33 pm EDT.

Check out Teslarati’s newsletters for prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket launch and recovery processes.

Space Reporter.

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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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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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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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