Connect with us

News

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)

Published

on

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.

Check out Teslarati’s Marketplace! We offer Tesla accessories, including for the Tesla Cybertruck and Tesla Model 3.

Advertisement
-

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.

Advertisement
Comments

Investor's Corner

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

Published

on

By

Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

Continue Reading

Investor's Corner

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.

Published

on

By

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.

Continue Reading

News

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.

Published

on

By

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.

Continue Reading