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Elon Musk says a SpaceX Falcon 9 rocket is about to be "destroyed in Dragon fire"

Sadly, this is a not a sight that will greet Falcon 9 booster B1046's fourth launch - Crew Dragon's critical In-Flight Abort test. (SpaceX)

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SpaceX CEO Elon Musk has officially confirmed that the company’s next Falcon 9 launch will destroy the flight-proven booster and upper stage “in Dragon fire”, a cryptic reference to the ultimate purpose of the sacrifice.

Known as SpaceX’s In-Flight Abort (IFA) test, the mission is designed not to place any particular payload in orbit but to demonstrate that Crew Dragon – the company’s first human-rated spacecraft – can ensure astronaut safety even if faced with a worst-case scenario during launch. IFA will mark Crew Dragon’s second dedicated abort test and second launch on a SpaceX Falcon 9 rocket, although the mission’s brand-new spacecraft will have to suffice with a suborbital jaunt before hopefully splashing down intact in the Atlantic Ocean.

If everything goes as planned, SpaceX has every intention of reusing the IFA Crew Dragon capsule on a future mission, although it’s unclear what that mission might look like. It’s unlikely that a reused SpaceX spacecraft will fly NASA astronauts anytime soon but it’s possible that the company will refurbish the vehicle for an entirely private astronaut launch or transform it into the first uncrewed launch of a next-generation Cargo Dragon (Dragon 2). Regardless, given the challenges posed by the In-Flight Abort, Crew Dragon’s survival is far from guaranteed.

Given that such an abort scenario is by definition a possibility, it’s likely the case that SpaceX’s engineers are almost certain that Crew Dragon should be able to survive such an ordeal, but the spacecraft will likely be pushed to its limits and it’s often much harder to ensure that everything works as intended at those limits.

In-Flight Abort by the numbers

Formerly scheduled to fly since-destroyed Crew Dragon capsule C201, SpaceX was forced to shuffle its spacecraft scheduling, reassigning Crew Dragon capsule C205 – originally expected to launch SpaceX’s first NASA astronaut mission – to support the In-Flight Abort. Featuring upgrades designed to prevent the failure mode that led to C201’s violent explosion, C205 will now have to survive a series of extremely challenging environments.

The IFA test is designed to prove that Crew Dragon can escape a failing Falcon 9 rocket during the most mechanically stressful point of launch. Occurring around 80-100 seconds after liftoff and known as Max Q, it’s the point where Falcon 9’s velocity and altitude combine to create the most friction and pressure the rocket’s windward parts will experience on their climb to orbit. For Crew Dragon, this means its SuperDraco abort engines will have to work fight upwards against air that is functionally (but not literally) much thicker than it is at other points during flight – a battle that will simultaneously put even more pressure (mechanical stress) on the spacecraft’s surfaces.

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Pictured with Starship and Super Heavy, Max Q can sometimes correlate with spectacular clouds that form and pulse along the nose of a rocket – caused because the pressure quite literally condenses the water vapor in the air. (SpaceX)

Purely from a numerical perspective, the pressure at Max Q is typically around 30-35 kPa (4.5-5 psi), which doesn’t sound like much but can easily become a force to be reckoned with when the surface area of the rocket or spacecraft being impacted is as large as Crew Dragon (let alone Starship). For reference, Crew Dragon capsules likely have a conical surface area on the order of 30,000 square inches (~19 m²), meaning that the spacecraft is subjected to a total mechanical load of 50-60 metric tons (~130,000 lbf) at Max Q.

Traveling as fast as Mach 2.5 (860 m/s) at an altitude of 28 kilometers (17 mi) at the point where Crew Dragon will ignite its abort thrusters and attempt to escape, that very act of escape will likely magnify the mechanical stresses on the capsule even further. During Crew Dragon’s 2015 Pad Abort, for example, the spacecraft went from a standstill to 155 m/s (345 mph) in 7 seconds – an average acceleration of about 2.3 Gs. Crew Dragon C205 could thus find itself traveling almost Mach 3 (more than a kilometer per second) just seconds after separating and may ultimately reach a peak altitude of almost 75 km (45 mi).

This is all to simply say that Crew Dragon is going to be subjected to an array of varying extremes in a very short period of time, during and after which it must still successfully control its orientation, avoid tumbling, detach its trunk section, and deploy a series of parachutes to achieve a fully-successful test. Additionally, the In-Flight Abort test will see Crew Dragon launch on an almost orbit-worthy Falcon 9 upper stage (lacking only a functional Merlin Vacuum engine) and thrice-flown booster B1046.

According to CEO Elon Musk, it simply is not going to be possible to prevent the historic booster – the first Falcon 9 Block 5 rocket ever launched – from being destroyed shortly after Crew Dragon attempts its escape. Once Dragon departs Falcon 9, the upper stage will likely be torn to shreds by the supersonic airstream suddenly buffeting it, ultimately exposing Falcon 9 B1046’s unchanged interstage – effectively a giant, open cylinder closed at its base.

Likely still travel supersonic, the results of the airstream entering Falcon 9’s interstage and finding no exit will likely be akin to a glass cup smashing mouth-first into a brick wall with a bowling ball taped to its bottom. Thankfully, Falcon 9 B1046 has already successfully supported three orbital-class launches since it debuted in May 2018, completing its third flight just seven months later. The booster will be missed and the opportunity cost (at least several more orbital-class launches) is definitely non-zero, but its sacrifice sill be for a good reason.

As Musk notes, if the In-Flight Abort goes as planned, it could pave the way for Crew Dragon’s first NASA astronaut launch – known as Demo-2 – as few as 6-8 weeks later. For now, Crew Dragon’s IFA test is scheduled to launch no earlier than (NET) January 18th, likely around 8 am EST (13:00 UTC).

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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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Tesla shows what Roadster drivers will see on screen before thruster activation

Tesla’s Roadster video reveals a fighter jet inspired cockpit with a 5,500 PSI thruster gauge.

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The next generation Tesla Roadster’s touchscreen, shown in Tesla’s first official look at the car’s interface. (Credit: Tesla/X)

Tesla has given future owners their clearest look yet at the cockpit of its next generation Roadster. In a 34 second video posted to X on Friday afternoon, the company walked through the car’s touchscreen with a caption: “Inspired by fighter jet cockpits, Roadster’s interface was designed around the pilot.”

The clip opens on a black screen with red graphics and a 3D wireframe of the car, which sits beside the Roadster’s squared off yoke. Tapping parts of the model brings up controls for the rear wing, including low drag and high downforce positions, along with a charging page with a charge limit bar and a small music player. A row of tabs along the bottom reads Home, Vehicle, Listen, Climate and Navigate.

Most of the video is spent in Track Mode. The dashboard shows a live circuit map, a list of session lap times, brake and motor temperatures, and pressure and temperature readouts for each tire. A setup page lets the driver pick Auto, Low Drag, High Downforce or Custom aero modes, adjust aero balance and brake balance, and switch stability and traction control off. Along the bottom, a status bar reads “Thruster · 5,500 PSI” next to a “Boost Ready” indicator.

That gauge ties the software to the hardware Tesla showed off near Waco, Texas on October 15. The Thrust and Rocket versions use cold gas thrusters fed by carbon overwrapped pressure vessels, and Tesla lists 0 to 60 mph times of under 0.9 seconds and under 0.59 seconds for them, as Teslarati detailed in its breakdown of the three Roadster configurations. The base Performance car relies on a fan and ground sealing system for grip, and the aero settings on screen match the active wings and suction setup covered in our look at how the Roadster generates downforce.

The Roadster layout is a departure from the rest of Tesla’s lineup. Instead of a map centered screen, the Roadster puts the car itself at the center of the home page, and Tesla’s Roadster page lists two smaller forward displays alongside the main touchscreen. Tesla has not said whether any of the Track Mode telemetry will make its way to the Model 3 Performance or other vehicles.

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The interface could still change before deliveries. Elon Musk said at the event that Roadster production will begin in 2028, and Tesla says the flagship Rocket version is not approved for public road use. Reservations are open with a $50,000 payment, while Thrust is listed as a limited release and Rocket is invite only.

Those who want to see the car in person will get their first chance this weekend. The Roadster goes on display in the lobby of the Petersen Automotive Museum in Los Angeles from October 24 to 27, according to Sawyer Merritt, the first time the public will be able to view it up close.

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Tesla reveals Optimus Academy, where robots teach themselves

Tesla has begun building production quality Optimus robots in Fremont and revealed its training plan.

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Concept rendering of Tesla Optimus in mass production

Tesla has started building Optimus on the high volume line it set up inside its Fremont factory, and the company says the robots coming off it are the first that meet the bar for a real product. “The bots coming off this line are the first production-quality bots that we have manufactured,” Tesla wrote in its third quarter shareholder letter, adding that it has “proven that the current manufacturing process for Optimus is suitable for a commercial product.”

The line sits in space that built the Model S and Model X until this spring. Tesla cleared the old vehicle line in 46 days, as Teslarati reported in July, to make room for robot production sized for one million units a year. On Wednesday’s earnings call, Elon Musk said most of the equipment for that capacity is already in Fremont, with output set to climb toward roughly 20,000 robots a week as the line ramps.

Musk described the ramp as a classic S curve. “The growth of Optimus is an S curve, but the initial curve is a shallow slope,” he said. The team is now refining the robot’s AI, electromechanical design, reliability and service life, and Musk expects that work to be finished by the end of next year, when Tesla plans to start delivering Optimus to outside companies for dangerous, repetitive and around the clock jobs.

The most interesting part of the call was how Tesla plans to teach the robots. Its cars send real driving data back to the AI team from millions of vehicles, but Optimus has no fleet like that yet. “A big difference with Optimus versus the cars is we don’t have this vast fleet of cars from which we can gather training data,” Musk said. Tesla’s answer is an Optimus Academy, where 10,000 to 20,000 robots will practice a wide range of tasks and feed what they learn into the next version of the model. Every unit off the Fremont line becomes a source of that training data.

Smarter hardware is on the way too. Tesla plans to put its AI5 chip into Optimus next year, and Musk said a new Optimus video should arrive within one or two months showing the robot completing tasks driven by AI rather than preprogrammed motions. He took aim at rival humanoid demos that only run scripted routines, saying those would not hold up in the real world.

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The supply chain is lining up behind the program. In September, Tesla certified Tuopu, Joyson and Sanhua as mass production partners for Optimus components. A far larger Optimus factory is also rising at Giga Texas, where drone footage from Joe Tegtmeyer showed the steel frame nearing completion, and Musk has pegged that plant’s long term target at 10 million robots a year.

Tesla executives also said Optimus production costs are trending toward the expected manufacturing cost of Cybercab, a sign the robot is being engineered for volume from the start. The hands remain the toughest piece of the design, a point Musk also made at the X Takeover event earlier this month, as Teslarati covered at the time, and that is where much of the current engineering effort is focused.

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The Starship moon landing number NASA and Elon Musk can’t agree on

Musk disputes NASA estimate of 22 Starship launches for Moon landing, predicting 6 to 8.

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Concept rendering of SpaceX Starship landing on the moon via Grok

Elon Musk is disputing a new NASA safety panel estimate of how many Starship launches it will take to put astronauts on the Moon, saying the real number will be less than half the panel’s figure.

On Thursday, NASA’s Aerospace Safety Advisory Panel held its quarterly public meeting. Panel member Charlie Precourt, a former NASA astronaut, flagged the fueling process for SpaceX’s lunar lander as a major risk for Artemis IV, the mission planned to land a crew on the Moon in 2028. “We need to keep our eyes on numerous required fuelings for the lander,” Precourt said, according to Ars Technica. “I think the last estimate is around 22 flights.”

Ars Technica’s Eric Berger posted the comment on X, and Musk replied. “That’s way too high,” Musk wrote. “Actual number will be more like 6 to 8.”

The disagreement comes down to a basic problem with sending a ship as large as Starship to the Moon. Starship burns nearly all of its propellant just reaching Earth orbit, so it cannot continue on to the Moon without stopping for a refill. SpaceX’s answer is a gas station in space. First, a Starship that works as a storage tank, called a depot, is launched into orbit. Then a series of tanker Starships launch one at a time, dock with the depot and pump their leftover propellant into it. Once the depot is full, the lunar lander version of Starship launches, docks, fills up and heads for the Moon.

Every tanker trip is its own full rocket launch, which is why the count matters. More launches mean more time, more cost and more chances for something to go wrong before astronauts ever leave Earth. Berger estimated that even if SpaceX reaches twice weekly Starship launches by the end of 2027, filling a depot at the panel’s number would still take roughly three months.

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How many tankers are needed depends mostly on how much propellant each one can carry to orbit and how much is lost along the way. Starship’s fuel and oxygen are stored at extremely cold temperatures, and some of it slowly boils off while waiting in orbit. More is lost in each transfer. NASA appears to be working from what Starship can lift today, while Musk’s range assumes a more capable rocket.

Musk has pushed back on higher counts before. In 2021, after a government document suggested 16 launches, he called that “extremely unlikely” and said eight tankers would be the most required.

Much of the answer depends on hardware SpaceX has not finished flying. As Teslarati noted earlier this year, the company plans to carry out the refueling process with its upgraded V3 Starship, and Precourt described Artemis IV as carrying “a large number of firsts.” He also praised NASA Administrator Jared Isaacman’s team for working to clear obstacles for both SpaceX and Blue Origin, whose Blue Moon lander does not rely on orbital refueling for its first mission.

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