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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.

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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.

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.

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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 already has a complete Robotaxi model, and it doesn’t depend on passenger count

That scenario was discussed during the company’s Q4 and FY 2025 earnings call, when executives explained why the majority of Robotaxi rides will only involve one or two people.

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Credit: @AdanGuajardo/X

Tesla already has the pieces in place for a full Robotaxi service that works regardless of passenger count, even if the backbone of the program is a small autonomous two-seater. 

That scenario was discussed during the company’s Q4 and FY 2025 earnings call, when executives explained why the majority of Robotaxi rides will only involve one or two people.

Two-seat Cybercabs make perfect sense

During the Q&A portion of the call, Tesla Vice President of Vehicle Engineering Lars Moravy pointed out that more than 90% of vehicle miles traveled today involve two or fewer passengers. This, the executive noted, directly informed the design of the Cybercab. 

“Autonomy and Cybercab are going to change the global market size and mix quite significantly. I think that’s quite obvious. General transportation is going to be better served by autonomy as it will be safer and cheaper. Over 90% of vehicle miles traveled are with two or fewer passengers now. This is why we designed Cybercab that way,” Moravy said. 

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Elon Musk expanded on the point, emphasizing that there is no fallback for Tesla’s bet on the Cybercab’s autonomous design. He reiterated that the autonomous two seater’s production is expected to start in April and noted that, over time, Tesla expects to produce far more Cybercabs than all of its other vehicles combined.

“Just to add to what Lars said there. The point that Lars made, which is that 90% of miles driven are with one or two passengers or one or two occupants, essentially, is a very important one… So this is clearly, there’s no fallback mechanism here. It’s like this car either drives itself or it does not drive… We would expect over time to make far more CyberCabs than all of our other vehicles combined. Given that 90% of distance driven or distance being distance traveled exactly, no longer driving, is one or two people,” Musk said. 

Tesla’s robotaxi lineup is already here

The more interesting takeaway from the Q4 and FY 2025 earnings call is the fact that Tesla does not need the Cybercab to serve every possible passenger scenario, simply because the company already has a functional Robotaxi model that scales by vehicle type.

The Cybercab will handle the bulk of the Robotaxi network’s trips, but for groups that need three or four seats, the Model Y fills that role. For higher-end or larger-family use cases, the extended-wheelbase Model Y L could cover five or six occupants, provided that Elon Musk greenlights the vehicle for North America. And for even larger groups or commercial transport, Tesla has already unveiled the Robovan, which could seat over ten people.

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Rather than forcing one vehicle to satisfy every use case, Tesla’s approach mirrors how transportation works today. Different vehicles will be used for different needs, while unifying everything under a single autonomous software and fleet platform.

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Tesla Cybercab spotted with interesting charging solution, stimulating discussion

The port is located in the rear of the vehicle and features a manual door and latch for plug-in, and the video shows an employee connecting to a Tesla Supercharger.

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Credit: What's Inside | X

Tesla Cybercab units are being tested publicly on roads throughout various areas of the United States, and a recent sighting of the vehicle’s charging port has certainly stimulated some discussions throughout the community.

The Cybercab is geared toward being a fully-autonomous vehicle, void of a steering wheel or pedals, only operating with the use of the Full Self-Driving suite. Everything from the driving itself to the charging to the cleaning is intended to be operated autonomously.

But a recent sighting of the vehicle has incited some speculation as to whether the vehicle might have some manual features, which would make sense, but let’s take a look:

The port is located in the rear of the vehicle and features a manual door and latch for plug-in, and the video shows an employee connecting to a Tesla Supercharger.

Now, it is important to remember these are prototype vehicles, and not the final product. Additionally, Tesla has said it plans to introduce wireless induction charging in the future, but it is not currently available, so these units need to have some ability to charge.

However, there are some arguments for a charging system like this, especially as the operation of the Cybercab begins after production starts, which is scheduled for April.

Wireless for Operation, Wired for Downtime

It seems ideal to use induction charging when the Cybercab is in operation. As it is for most Tesla owners taking roadtrips, Supercharging stops are only a few minutes long for the most part.

The Cybercab would benefit from more frequent Supercharging stops in between rides while it is operating a ride-sharing program.

Tesla wireless charging patent revealed ahead of Robotaxi unveiling event

However, when the vehicle rolls back to its hub for cleaning and maintenance, standard charging, where it is plugged into a charger of some kind, seems more ideal.

In the 45-minutes that the car is being cleaned and is having maintenance, it could be fully charged and ready for another full shift of rides, grabbing a few miles of range with induction charging when it’s out and about.

Induction Charging Challenges

Induction charging is still something that presents many challenges for companies that use it for anything, including things as trivial as charging cell phones.

While it is convenient, a lot of the charge is lost during heat transfer, which is something that is common with wireless charging solutions. Even in Teslas, the wireless charging mat present in its vehicles has been a common complaint among owners, so much so that the company recently included a feature to turn them off.

Production Timing and Potential Challenges

With Tesla planning to begin Cybercab production in April, the real challenge with the induction charging is whether the company can develop an effective wireless apparatus in that short time frame.

It has been in development for several years, but solving the issue with heat and energy loss is something that is not an easy task.

In the short-term, Tesla could utilize this port for normal Supercharging operation on the Cybercab. Eventually, it could be phased out as induction charging proves to be a more effective and convenient option.

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Tesla confirms that it finally solved its 4680 battery’s dry cathode process

The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.

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tesla 4680
Image used with permission for Teslarati. (Credit: Tom Cross)

Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years. 

The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.

Dry cathode 4680 cells

In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.

The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”

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Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.

4680 packs for Model Y

Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla: 

“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”

The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.

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