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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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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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Investor's Corner

Tesla uber bull Ron Baron says ‘the time to buy the stock is now’

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Credit: Tesla

In a new interview on Wednesday, Tesla uber bull Ron Baron said that anyone looking to buy the company’s stock should do so as soon as they can.

Baron, founder and CEO of Baron Capital and one of Tesla’s most persistent institutional bulls, used a CNBC Squawk Box appearance on Wednesday to deliver a familiar message with fresh urgency: In his opinion, Tesla stock is a buy:

“The time to buy the stock is now. FSD is catching on, and it’s going to be bigger and bigger. 55% of new buyers are buying it (Teslas) with FSD. It’s going to be everywhere. It’s safer.”

The Baron Capital frontman’s case is built around Full Self-Driving. Tesla reported 1.48 million active FSD subscriptions in the second quarter, up 56 percent year over year, and company officials have said roughly 55 percent of new North American deliveries left with a subscription enabled.

Baron framed that attach rate as proof the product is moving from enthusiast extra to default expectation, and as a reason software, not just vehicle volume, should drive the next phase of value.

His conviction on Tesla shares is not theoretical, as Baron Capital made its first Tesla investment in 2014, after years of meetings that began around the 2010 IPO roadshow. The firm later built a large SpaceX position starting in 2017.

Baron said those Musk-led bets have generated about $30 billion of the $71 billion in profits Baron Capital has produced for clients. He put the firm’s current exposure at roughly $25 billion in SpaceX and $5 billion in Tesla. Personally, he described SpaceX as his largest holding, at about $5 billion, with about $1.5 billion in Tesla and additional Tesla exposure through the firm’s funds.

That concentration is also a statement of loyalty. Asked about talk of a SpaceX-Tesla combination, Baron said he had already walked Elon Musk through arguments for and against a deal, then declined to repeat them on air. His public position was simpler: “Whatever you decide is better is what I’m going to support,” he said to Musk.

Baron also said that he picked up the farewell edition of the Model S after Tesla decided to sunset the vehicle earlier this year, calling it his favorite car he’s ever driven.

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