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SpaceX first orbital spacecraft set to smash reusability record on last launch

SpaceX's Cargo Dragon (Dragon 1) spacecraft is ready to end a long and productive career with a bang. (NASA)

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The first orbital spacecraft designed and built by SpaceX is set to smash a reusability record on its 20th and final International Space Station (ISS) resupply launch, hopefully ending an exceptional career with yet another noteworthy achievement.

After a rocket-related hardware issue forced a four-day delay, a flight-proven Cargo Dragon spacecraft and Falcon 9 rocket are set to lift off no earlier than (NET) 11:50 pm EST, March 6th (04:50 UTC, March 7th) on NASA’s 20th and final SpaceX Commercial Resupply Services (CRS-20) mission. Although SpaceX’s final CRS1 launch, 20th mission milestone, flight-proven Dragon, and fairly quick Falcon 9 booster turnaround are all significant and exciting in their own ways, the most noteworthy technical aspect of CRS-20 can be found in the Dragon capsule that will soon be perched atop the tip of the rocket.

Shared on March 1st alongside confirmation of a successful Falcon 9 wet dress rehearsal (WDR) and static fire at its Cape Canaveral, Florida Launch Complex 40 (LC-40) pad, SpaceX revealed that Cargo Dragon capsule C112 (C1: Dragon 1; 12: capsule #12) will be supporting CRS-20 as early as this Friday. If all goes according to plan, it will be the spacecraft’s third cargo mission to the ISS since February 2017, becoming the third orbital SpaceX vehicle to do so. Even more significantly, C112 is poised to crush Cargo Dragon’s own previous record for the shortest time between two orbital launches.

An overview of LC-40 during Falcon 9’s December 2018 CRS-16 Dragon launch. (SpaceX)

Back in June 2017, SpaceX became the first private company in history to successfully reuse an orbital-class spacecraft on its CRS-11 Cargo Dragon mission, itself the first private spacecraft in history to successfully rendezvous with the space station. Since then, all but one CRS mission has featured an orbit-proven Dragon capsule, making CRS-20 the ninth time SpaceX will attempt to launch a spacecraft into orbit for the second (or third) time.

Cargo Dragon capsule C108 became the first private spacecraft to complete three orbital missions on August 27th, 2019 after reentering and splashing down in the Pacific Ocean. (SpaceX)

In other words, nearly half of all of SpaceX’s NASA CRS missions have featured flight-proven spacecraft, while several have also launched with flight-proven Falcon 9 boosters. Still, while extremely impressive that SpaceX has managed to convince the risk-averse space agency to fly several dozen tons of critical hardware on flight-proven rockets and spacecraft, Cargo Dragon capsule reuse has always been a comparatively lengthy and complex process.

Back in July 2017, just a month after SpaceX’s first successful Cargo Dragon reuse, CEO Elon Musk offered some insight into the capability’s potential value.

“Musk said he expects the next Dragon reuse and all future reuses to save SpaceX nearly 50% of the cost of manufacturing an entirely new spacecraft. Musk admitted that the first refurbishment of Dragon likely ended up costing as much or more than a new vehicle, but this is to be expected for the first attempt to reuse any sort of space hardware that must survive some form of reentry heating and saltwater immersion.”

Teslarati.com — July 21st, 2017

Supercomputer
Cargon Dragon’s CRS-11 mission marked the world’s first reuse of a private orbital-class spacecraft. (SpaceX)

Ultimately, SpaceX has almost certainly realized Musk’s ambition of cutting the cost of orbital space station resupply missions in half (at least). Scheduled to launch on March 6th, Cargo Dragon capsule C112 last launched in December 2018, reentering Earth’s atmosphere and splashing down on January 13th, 2019. With CRS-20, the capsule could thus crush the previous record – 19 months – by more than 25%. Measured from splashdown to the capsule’s shipment to the launch pad, SpaceX may have spent less than a year refurbishing the Cargo Dragon spacecraft, likely more than a 50% improvement over all past refurbishment operations.

A simplified version of Crew Dragon is scheduled to begin uncrewed space station cargo missions with CRS-21 later this year. (SpaceX)

CRS-20 should thus mark a climactic and fitting end to Cargo Dragon 1’s nine-year spaceflight career. While bittersweet that the spacecraft and its many siblings will likely never fly again, Musk has said that Dragon 2 (Crew Dragon) – the spacecraft intended to replace it – is dramatically easier (and thus cheaper) to reuse than Dragon 1. As such, SpaceX should have no issue continuing its trend of lowering the cost of access to space after it begins space station cargo deliveries under its CRS2 NASA contract later this year.

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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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