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Boeing's Starliner and SpaceX's Crew Dragon spacecraft stand vertical at their respective launch pads in December 2019 and January 2020. Crew Dragon has now performed two successful full-up launches to Starliner's lone partial failure. (Richard Angle) Boeing's Starliner and SpaceX's Crew Dragon spacecraft stand vertical at their respective launch pads in December 2019 and January 2020. Crew Dragon has now performed two successful full-up launches to Starliner's lone partial failure. (Richard Angle)

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SpaceX set to launch NASA astronauts first after Boeing narrowly avoids catastrophe in space

Boeing's Starliner and SpaceX's Crew Dragon spacecraft stand vertical at their respective launch pads roughly six weeks apart. (Richard Angle)

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SpaceX is set to become the first private company to launch NASA astronauts as few as three months from now, all but guaranteed after Boeing’s competing Starliner spacecraft narrowly avoided a catastrophe in space on its orbital launch debut.

The ultimate purpose of NASA’s Commercial Crew Program (CCP) is to ensure that the US is once again able to launch its own astronauts into orbit and to the International Space Station (ISS) – a capability the country has not possessed since it prematurely canceled the Space Shuttle in 2011. In a logical step, NASA decided to fund two independent companies to ensure that astronaut launch capabilities would be insulated against any single failure, ultimately awarding contracts to Boeing and SpaceX in 2014. Boeing did actually try to have Congress snub SpaceX back in 2014 and solely award the contract to Starliner, but the company thankfully failed.

As a result, SpaceX beating Boeing on the (not-a-) race to launch NASA astronauts to the International Space Station (ISS) would represent an immense and deeply embarrassing upset in the traditional aerospace industry – essentially a case of David and Goliath. For the better part of a decade, Congress, most industry officials, and Boeing itself have argued ad nauseum the Starliner spacecraft was clearly a far safer bet than anything built by SpaceX – Boeing, obviously, has far more experience (“heritage”) in the spaceflight industry. However, multiple “catastrophic” failures during Boeing’s recent Starliner ‘Orbital Flight Test’ (OFT) paint a far uglier picture.

The SpaceX Crew Dragon capsule and Boeing CTS-100 Starliner are pictured here during separate pad abort tests. (SpaceX/NASA)

As its PR team and executives will constantly remind anyone within earshot, Boeing helped build the first stage of the Saturn V rocket, while a company it bought years after the fact (Rockwell) did technically buy the company (North American) that built the spacecraft (Apollo CSM) that carried NASA astronauts from the Earth to the Moon (and back). Rockwell (acquired by Boeing) also built all five of NASA’s Space Shuttle orbiters.

In the 1990s, Boeing – set to lose a competition to build an expendable rocket for the US military – acquired McDonnell Douglas at the last second, slapping a Boeing sticker on the Delta IV rocket – designed and built by MD. Boeing then conspired to steal trade secrets from Lockheed Martin (bidding Atlas V) and used that stolen info to mislead the USAF about the real cost of Delta IV, thus securing the more lucrative of two possible contracts. This is all to point out the simple fact that Boeing has far less real experience designing spacecraft than it tends to act like it does.

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Boeing’s Starliner spacecraft sits atop a ULA Atlas V rocket at the LC-41 launch pad ahead of its doomed orbital flight test (OFT). (Richard Angle)

As such, it’s substantially less surprising than it might otherwise be that Boeing’s Starliner spacecraft has had such a rocky orbital launch debut. Preceded just a matter of weeks by a quality assurance failure that prevented one of Starliner’s four parachutes from deploying after an otherwise-successful pad abort test, a second Starliner spacecraft launched atop an Atlas V rocket on its orbital launch debut (OFT) on December 20th, 2019. Atlas V performed flawlessly but immediately after Starliner separated from the rocket, things went very wrong.

Bad software ultimately caused the spacecraft to perform thousands of uncommanded maneuvering thruster burns, depleting a majority of its propellant before Boeing was able to intervene. Starliner managed to place itself in low Earth orbit (LEO), but by then it had nowhere near enough propellant left to rendezvous and dock with the ISS – one of the most crucial purposes of the uncrewed flight test. Unable to complete that part of the mission, Boeing instead did a few small tests over the course of 48 hours in orbit before commanding the spacecraft’s reentry and landing on December 22nd.

Starliner successfully landed on December 22nd after a partial failure in orbit. (NASA – Bill Ingalls)

But wait, there’s more!

As it turns out, although both NASA and Boeing inexplicably withheld the information from the public for more than two months, Boeing’s OFT Starliner spacecraft reportedly almost suffered a second major software failure just hours before reentry. According to NASA and Boeing comments in a press conference held only after news of that second failure broke after an advisory panel broached the issue in February 2020, a second Starliner software bug – caught only because the first failure forced Boeing to double-check its code – could have had far more catastrophic consequences.

NASA officials stated that had the second bug not been caught, some of Starliner’s thruster valves would have been frozen, either entirely preventing or severely hampering the spacecraft’s detached trunk from properly maneuvering in orbit. Apparently, that service module (carrying fuel, abort engines, a solar array, and more) could have crashed into the crew module shortly after detaching from it. Unsurprisingly, that ‘recontact’ could have severely damaged the Starliner crew capsule, potentially making reentry impossible (or even fatal) if its relatively fragile heat shield bore the brunt of that impact.

SpaceX has undeniably suffered its own significant failures, most notably when flight-proven Crew Dragon capsule C201 exploded moments before a static fire test, but the company has already proven that it fixed the source of the failure with the spacecraft’s second successful launch on a Falcon 9 rocket. Ultimately, it’s becoming nearly impossible to rationally argue that Boeing’s Starliner will be safer than SpaceX’s Crew Dragon – let alone worth the 40% premium Boeing is charging NASA and the US taxpayer.

As of February 2020, Crew Dragon has successfully docked with the ISS and completed two successful Falcon 9 launches in just nine months. (Richard Angle)

According to Ars Technica’s Eric Berger, Crew Dragon’s inaugural astronaut launch is now tentatively scheduled as early as late-April to late-May 2020. Paperwork – not technical hurdles – is currently the source of that uncertainty, and all Demo-2 mission hardware (Falcon 9 and Crew Dragon) is either already in Florida or days away from arriving.

Due to the combination of similar software failures Starliner suffered during its first and only launch, Boeing now has to review the entirety of the spacecraft’s software – more than a million lines of code – before NASA will allow the company to launch again. There’s also a very good chance that Boeing will now have to repeat the Orbital Flight Test, potentially incurring major delays. In short, it would take nothing less than a miracle – or NASA making a public mockery of itself for Boeing’s benefit – for Starliner to launch astronauts before SpaceX.

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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 is using a redesigned Cybertruck battery cell to mitigate Semi challenges

It is perhaps the most recent example of Tesla using unique engineering prowess and cross-pollinating vehicle elements to solve common problems, something it does better than most companies out there.

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Credit: Tesla

Tesla revealed that it is utilizing redesigned Cybertruck battery cells in its Long Range Semi to mitigate some pertinent challenges that come with long-haul logistics.

It is perhaps the most recent example of Tesla using unique engineering prowess and cross-pollinating vehicle elements to solve common problems, something it does better than most companies out there.

Tesla’s long-awaited Semi truck is entering production at its Nevada Gigafactory, and fresh factory footage reveals a clever evolution in its battery technology.

The Long Range variant, designed for up to 500 miles of real-world range, relies on a structural battery pack that uses the same 4680-form-factor cells found in the Cybertruck.

However, Tesla engineers have completely redesigned the pack’s architecture—shifting from the flat, pancake-style modules typical in passenger vehicles to a compact, vertical cubic layout. This change isn’t just about cramming more energy into the chassis; it’s a targeted solution to one of electric trucking’s biggest headaches: range loss in cold climates.

Dan Priestley, Head of the Tesla Semi program, said:

“We’re using essentially the same cell out of Cybertruck, but our cars packs are more like a pancake. Whereas these are more like a cube. You get a lot of energy stored in a small space. You can only do this if you design the vehicle to be electric from the ground up.”

In conventional EVs, battery packs are laid out horizontally in wide, flat arrays to fit under the floor. While this works for cars and even the Cybertruck’s structural pack, it exposes a large surface area to the elements.

Heat escapes quickly, especially overnight when the truck is parked. Cold temperatures slow chemical reactions inside lithium-ion cells, reducing available energy and forcing the vehicle to expend extra power warming the battery and cabin.

Real-world tests on vehicles like the Cybertruck show winter range losses of 20-40 percent, depending on conditions. For long-haul truck drivers operating in Canada, Scandinavia, or the northern U.S., this “silent killer” means unplanned stops, reduced payloads, and higher operating costs.

From personal experience, cold weather still impacts EV batteries even with various inventions and strategies that companies have come up with. In the cold Pennsylvania winter, charging was much more frequent for me due to range loss due to temperatures.

Tesla’s cubic battery pack flips the script. By arranging the 4680 cells in tall, dense vertical stacks, the pack minimizes external surface area relative to its volume—essentially turning the battery into its own thermal blanket.

Factory video from the Semi assembly line shows these large, yellow-green structural modules mounted directly onto the chassis, forming a near-cube shape.

The reduced exposure helps the pack retain heat generated during operation, keeping cells closer to their optimal temperature even after hours in sub-zero conditions.

The design doesn’t stop there. Tesla pairs the cubic pack with an advanced heat pump system that actively recycles thermal energy from the motors, brakes, and even ambient air.

Tesla reveals various improvements to the Semi in new piece with Jay Leno

Unlike passive systems in earlier EVs, this architecture transfers waste heat back into the battery, maintaining readiness for morning departures without draining the pack.

Executives have noted that the combination, cubic geometry plus intelligent thermal management, dramatically cuts overnight cooldown and range degradation, making the Semi viable for 24/7 fleet operations in harsh winters.

Beyond cold-weather performance, the redesigned pack integrates structurally with the truck’s frame, enhancing rigidity while simplifying assembly. Production footage shows workers installing the massive modules early in the line, signaling that the Semi’s battery is now a core chassis component rather than an add-on.

Using proven 4680 cells keeps costs down and leverages Tesla’s scaled manufacturing know-how from Cybertruck and Model Y lines.

Tesla’s focus on ramping up Semi output will lean on small innovative steps like this one. Truckers are not immune to traveling in cold weather conditions, and changes like this one will help make them more effective while also increasing output by logistics operators who choose to go all-electric with the Tesla Semi.

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SpaceX is keeping the Space Station alive again this weekend

SpaceX’s Falcon 9 launches Northrop Grumman’s Cygnus NG-24 to the ISS with 11,000 pounds of cargo Saturday.

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SpaceX is targeting April 11 for the launch of Northrop Grumman’s Cygnus XL cargo spacecraft to the International Space Station, carrying over 11,000 pounds of supplies, science hardware, and equipment for the Expedition 73 crew aboard. Liftoff is set for 7:41 a.m. ET from Space Launch Complex 40 at Cape Canaveral Space Force Station, with a backup window available April 12 at 7:18 a.m. ET.

The mission, officially designated NG-24 under NASA’s Commercial Resupply Services program, names its spacecraft the S.S. Steven R. Nagel in honor of the NASA astronaut who flew four Space Shuttle missions and logged over 723 hours in space before his death in 2014. Unlike SpaceX’s own Dragon capsule, which docks autonomously, Cygnus relies on NASA astronauts to capture it using a robotic arm before it is berthed to the space station’s module for unloading. When the mission wraps up around October, the Cygnus will depart loaded with station trash and burn up on reentry.

Countdown: America is going back to the Moon and SpaceX holds the key to what comes after

This is the second flight of the Cygnus XL configuration, which debuted on NG-23 in September 2025 and offers a roughly 20% increase in cargo capacity over the previous design. Northrop Grumman switched to Falcon 9 launches after its own Antares 230+ rocket was retired in 2023 following supply chain disruptions from the war in Ukraine.

The upcoming cargo includes a new module to advance quantum research, and an investigation studying blood stem cell production in microgravity with potential therapeutic applications on Earth.

The NG-24 mission is one piece of a much larger picture for SpaceX and the U.S. government. As Teslarati reported, SpaceX has become an indispensable launch provider for U.S. national security missions, picking up a $178.5 million Space Force contract in April 2026 to launch missile tracking satellites, while also holding roughly $4 billion in NASA contracts tied to the Artemis lunar program.

At a time when no other American rocket can match the Falcon 9’s combination of reliability, cost, and launch cadence, Saturday’s mission is a straightforward reminder of how much the U.S. government now depends on a single commercial provider to keep its astronauts supplied and its satellites flying.

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Tesla hits FSD hackers with surprise move

In recent weeks, the company has begun remotely disabling FSD capabilities on affected vehicles, and in some instances, permanently revoking access even for owners who paid thousands of dollars for the feature.

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Tesla is cracking down on hackers who have figured out a way to utilize third-party programs to activate Full Self-Driving (FSD) in their vehicles — despite the suite not being approved for use in their country.

Tesla has launched a sweeping enforcement campaign against owners using third-party hardware hacks to activate FSD software in countries where the advanced driver-assistance system remains unregulated or unapproved.

In recent weeks, the company has begun remotely disabling FSD capabilities on affected vehicles, and in some instances, permanently revoking access even for owners who paid thousands of dollars for the feature.

Reports of the crackdown have surfaced across Europe, China, Japan, South Korea, and the UK, marking a significant escalation in Tesla’s efforts to enforce regional software restrictions.

FSD is Tesla’s flagship supervised autonomy package, which is available in several countries across the world. Currently limited by regulatory hurdles, it has not received full approval in most markets outside of the United States due to various things, such as safety standards, data privacy, and local traffic laws.

However, the company is working to expand its availability globally. Nevertheless, Tesla has installed the necessary hardware on vehicles globally, but locks the features based on geographic location.

Some owners have taken accessing FSD into their own hands, using jailbreak or bypass devices.

These “jailbreak” tools, typically €500 USB-style modules that plug into the vehicle’s Controller Area Network (CAN) bus, intercept signals to spoof approvals and unlock FSD, including advanced navigation, Autopark, and Summon features.

Hackers in Poland, Ukraine, and elsewhere have distributed the devices, with some claiming they work on HW3 and HW4 vehicles and can be unplugged to restore stock settings. In China alone, over 100,000 owners reportedly installed such modifications.

Tesla’s response has been swift and uncompromising. Recently, the company began sending in-car notifications and emails warning owners that unauthorized modifications violate terms of service, compromise vehicle safety systems, and expose cars to cybersecurity risks.

The email communication read:

“Your vehicle has detected an unauthorized third-party device. As a precaution, some driver assistance functions have been disabled for safety reasons. A software update will be available soon. Once you install the update, some features may be enabled again.”

Vehicles detected using the hacks have had FSD capabilities remotely disabled without refund. In some cases, owners report permanent bans, even if they had legitimately purchased the software package.

Tesla’s hardline stance underscores its commitment to regulatory compliance and safety.

Tesla has long argued that unsupervised FSD requires rigorous validation, and premature activation could endanger drivers and bystanders.

The crackdown sends a clear-cut message to those who are bypassing the FSD safeguards, but there are greater implications for Tesla if something were to go wrong. This is an understandable way to protect the company’s reputation for its FSD suite.

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