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A 2021 SpaceX Odyssey: Dragon aces third astronaut launch, docks with space station

From one Crew Dragon to another: NASA astronaut Mike Hopkins watched Crew-2 Dragon C206's second ISS docking through Crew-1 Dragon C207's window. (NASA)

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Early on Saturday morning, SpaceX Crew Dragon ‘Endeavour’ (capsule C206) – carrying four international astronauts – flawlessly docked with the International Space Station (ISS) for the second time in less than a year.

Capping off a smooth 24 hours of free-flight following an equally successful Falcon 9 launch on Friday, April 23rd, Dragon’s third crewed space station arrival was captured in spectacular fashion – thanks in part to the presence of a separate Crew Dragon vehicle already docked to the orbiting outpost. Recently swapped between the two ISS docking ports capable of supporting Dragons, Crew-1 NASA astronaut Mike Hopkins had – by far – the best view in the house of Crew-2’s space station rendezvous while looking out the window of the other Crew Dragon on orbit.

Former NASA flight director and Space Shuttle program manager Wayne Hale put it best, stating that SpaceX “[made] it look easy” with a “perfectly successful [Crew-2] launch and docking” – the company’s third astronaut launch and space station rendezvous since May 2020.

Falcon 9 and Crew Dragon launch towards the ISS for the fourth time. (Richard Angle)
Crew Dragon C206 approaches the ISS for the second time in 11 months. (NASA)

After a mere three days of delays – one for weather – from an April 20th (4/20) target set almost three months earlier, Crew Dragon lifted off on SpaceX and NASA’s Crew-2 mission shortly before dawn on April 23rd. As the rocket rapidly carried Dragon and its passengers from sea level to dozens of kilometers above the Earth’s surface, it sailed into sunlight, producing a spectacle that stretched across a vast swath of the pre-dawn sky as the sun lit up Falcon 9’s second stage exhaust plume.

(Richard Angle)

The four astronauts aboard the flight-proven Dragon were equally amazed as the inky black vacuum outside their spacecraft’s windows turned to blinding, unfiltered sunlight. One spectacle and a flawless trip into orbit on Falcon 9 behind them, French European Space Agency (ESA) astronaut Thomas Pesquet caught a glimpse of the rocket’s expended second stage effectively flying in formation a few miles below Crew Dragon.

Crew-2’s Falcon 9 second stage (S2) and Merlin Vacuum engine were easily visible from the free-flying capsule – likely not long after the rocket completed a successful deorbit burn. (Thomas Pesquet – ESA)

After almost exactly 24 hours on its own and five major Draco thruster orbit-raising and trajectory-matching burns, as well as an unwelcome collision avoidance warning that ultimately turned out to be a false alarm, Crew Dragon capsule C206 completed its second space station docking without delay around 5am on April 24th. Pesquet has published several dozen excellent photos of the flight and docking, offering the best look yet at what life aboard a free-flying Dragon is really like for the four astronauts packed into a volume – as he himself notes – roughly equivalent to a large car’s cabin.

Japanese (JAXA) astronaut Akihiko “Aki” Hoshide takes a nap beside one of Dragon’s two windows. (Thomas Pesquet)
Several dozen miles out, Crew-2 spotted the football-field-sized ISS as a tiny speck floating in space. (Thomas Pesquet)

With its successful arrival, SpaceX – for the first time ever – had two separate Crew Dragon spacecraft docked to ISS simultaneously, marking the first of at least two more Dragon ‘hand-off’ milestones to come. Though NASA nominally planned to have Commercial Crew providers SpaceX and Boeing essentially take turns on operational astronaut ferry missions, the latter company’s Starliner spacecraft is more than a year and a half behind schedule and is unlikely to perform its first crewed demonstration flight before Q1 2022.

In other words, SpaceX has been forced to mature its Crew Dragon program much faster than expected to complete at least four back-to-back astronaut launches in ~17 months, while NASA is effectively dependent on the company to ensure the ISS remains fully crewed from May 2020 to sometime in 2022.

(NASA)
A spectacular front-seat view of Crew-2’s ISS arrival through the window of a different Dragon. (Mike Hopkins – NASA)

Following Crew-2’s smooth arrival, Crew-1’s Crew Dragon and its four-astronaut crew will return to Earth as early as April 28th. Sometime in October or November 2021, SpaceX will repeat that hand-off process once again when it launches Crew-3 and recovers Crew-2. There is a distant chance Boeing will have completed two successful test flights and be ready for Starliner’s operational astronaut launch debut in early 2022, but it’s arguably much more likely that SpaceX will also perform a third hand-off between Crew-3 and Crew-4 sometime in Q2 2022 before finally handing over the reins to Starliner.

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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.

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

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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