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Report: SpaceX to launch at least five back-to-back Crew Dragon missions for NASA
Update: Wasting no time at all, NASA has confirmed the Ars Technica report one day later, announcing that rookie astronauts Nicole Mann and Josh Cassada have been reassigned from Boeing Starliner missions to SpaceX’s Crew-5 Crew Dragon launch – currently no earlier than August 2022.
Ars Technica’s Eric Berger reports that NASA has begun the process of moving a number of astronauts assigned to Boeing’s ailing Starliner spacecraft to a SpaceX Crew Dragon mission scheduled no earlier than August 2022.
Per sources close to Berger, NASA has chosen to reassign two rookie astronauts to Crew Dragon as hopes of a crewed Starliner launch – and thus an opportunity for them to gain hands-on spaceflight experience – in the next 6-12 months continue to wither. Barring surprises, the implied change of plans behind those actions means that SpaceX now appears to be scheduled to fly five operational NASA Crew Dragon missions back to back before Boeing’s Starliner flies a single astronaut – let alone its first operational mission with four crew aboard.
In December 2019, nine months after Crew Dragon’s own uncrewed March 2019 debut, Starliner lifted off for the first time on a ULA Atlas V rocket. However, whereas Crew Dragon performed a practically flawless orbital launch, space station rendezvous, docking, departure, reentry, and splashdown on its first try, Starliner’s Orbital Flight Test (OFT) went horribly wrong as soon as it separated from Atlas V.
Due to shoddy prelaunch testing that failed to detect several gaping holes in Starliner’s software, the spacecraft effectively lost control as soon as it was under its own power. Aside from making ground communication and control far harder, Starliner burned through most of its propellant and pushed most of its maneuvering thrusters past their design limits in the first hour or two after launch. Due to the catastrophic software failure and lack of propellant margins, NASA unsurprisingly called off a planned space station rendezvous and docking attempt and Boeing ultimately ordered Starliner to reenter a few days after launch.
Mere hours before reentry, Boeing apparently detected and fixed another major software error at the last second, potentially preventing Starliner’s propulsion and service module from smashing into the capsule’s fragile heat shield and dooming the spacecraft to burn up during reentry. Ultimately, it’s likely that the only reason Boeing didn’t suffer a total loss of vehicle (LOV) during Starliner’s OFT debut spacecraft was dumb luck. Had the initial clock error been worse, Starliner could have failed to reach orbit entirely or burned through all of its propellant, resulting in an uncontrolled reentry. Had there been no clock issue, it’s hard to imagine that Boeing’s software team would have attempted the panicked, impromptu bug hunt that detected and fixed the service module recontact issue.
Now, 22 months after Starliner’s catastrophic OFT, Boeing has been forced to stand down from a second self-funded orbital flight test (OFT-2) due to the last-second discovery of more than a dozen malfunctioning valves on the second spacecraft’s service module. Aside from raising the question of how Boeing and NASA yet again failed to detect a glaring Starliner issue until the day of launch, Starliner’s valve issues appear likely to cause another multi-month delay as Boeing is forced to investigate the problem, find the root cause, and implement a fix on all impacted service modules.
NASA reassigning some of the astronauts scheduled to helm Starliner on its Crewed Flight Test (CFT) and first operational mission to Crew Dragon’s August 2022 Crew-5 launch seemingly implies that the space agency is not confident that Boeing will have completed Starliner OFT-2, passed extensive post-flight reviews, and readied another Starliner for CFT by Q3 2022. Given that NASA took some 14 months to OK Crew Dragon’s Demo-2 crewed flight test after Demo-1’s March 2019 success and a catastrophic April 2019 failure during a ground test of the recovered capsule, it’s not unreasonable to assume that NASA will take about a year after OFT-2 to approve Starliner’s first crewed flight test.
If significant issues arise during OFT-2, which is now unlikely to occur before early 2022, a year-long gap is even more likely. Ultimately, that means that there is now a significant chance that SpaceX’s Crew Dragon spacecraft will complete not just five – but six – back-to-back operational NASA astronaut launches before Starliner is ready for its first operational ferry mission. SpaceX, in other words, is now expected to singlehandedly hold the line and ensure biannual NASA access to and from the International Space Station (ISS) for more than two years despite charging NASA $2 billion less than Boeing (~$5B vs ~$3B) to develop Crew Dragon.
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Tesla’s Cybercab battery design could make robotaxis even cheaper
Tesla built the Cybercab’s battery pack with spare room for a future switch to LFP.
Tesla built the Cybercab’s battery pack with empty space inside it on purpose, and the reason points to a cheaper robotaxi down the road.
Robert Sumpf, Tesla’s director of mechanical design engineering for battery modules and packs, said the extra room beside and beneath the Cybercab’s modules was left there so the company can move to lithium iron phosphate cells later. “So, we protected this pack to go to an even lower energy dense chemistry as we scale and need to bring LFP into the platform,” Sumpf said in a Cybercab deep dive with Munro Live.
The Cybercab runs on Tesla’s own 4680 cells with a nickel chemistry today. LFP cells store less energy for their size, so a straight swap would cut range. The reserved space lets Tesla add more LFP cells to make up the difference. In return, Tesla would get cells that cost less, run cooler and survive more charge cycles. LFP became the most used EV battery chemistry in the world last year.
Not all of that room was planned for a chemistry change. Lars Moravy, Tesla’s Vice President of Vehicle Engineering, said part of it exists because “we didn’t need as many batteries as we thought we did.” Tesla told Sandy Munro in early 2025 that it was targeting a Cybercab pack under 50 kWh with close to 300 miles of range.
The pack also breaks from the structural design Tesla used in some Model Y and Cybertruck builds. Instead of potting hundreds of cells into one block, the Cybercab uses four separate, individually sealed modules, so a bad module can be replaced without scrapping the whole pack. Sumpf was blunt about the older approach, giving the Model Y structural battery “a grade D” because it was hard to build and nearly impossible to repair. He estimated a fully structural pack gains about 10% more cell volume, but said “the issue is the service cost.”
That cost matters more for a car that rarely sits parked. Cybercab chief engineer Eric Earley said replacing an entire pack “before half a million miles is a killer on cost,” which is why remanufacturing and serviceability were built into the design from the start.
The same Munro Live tour produced Moravy’s admission that the Cybercab line at Giga Texas is now outpacing Robotaxi deployments, along with a look at the robotaxi’s unorthodox paint process. Tesla is aiming to deliver the first Cybercabs to outside customers by the end of 2026, though Elon Musk has said the vast majority will stay owned by Tesla and run as a transport service.
Sumpf did not give a date for an LFP version, name a cell supplier or say how a chemistry change would affect range. For now, the 4680 cars keep piling up: Texas DMV records from Tuesday list 544 Cybercabs authorized for Tesla’s Robotaxi fleet, more than the 507 Model Ys on the same roster for the first time.
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 CEO Scott Kirby calls Starlink “the biggest competitive advantage,” but says it’s temporary.
“I think it’s the biggest competitive advantage. And it’s temporary. Like it’s not, everybody eventually is going to have high speed low earth orbit internet connectivity. It’s going to be a must-have. But we are going to have a few years of being the only airline that has it at scale, and that’s our mission.”
“I think we’re going to convince customers that United is the best airline and we’re going to get customers to switch their loyalty, to get our credit card, switch their loyalty to United. Not because of Starlink. They’re going to try us for Starlink and they’re going to stay with all the other technology, and everything else is better, and the technology in particular is so much better than technology other, and it’s accelerating because we’ve got the right tech stack, and because we’re like, our gap is getting wider and wider with our technology every day.”
Next: LAX becomes United’s first 100% Starlink hub in the first half of next year, and the United app will show your Starlink odds for each flight. https://t.co/hToyFWaWj7
— TESLARATI (@Teslarati) October 27, 2026
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.
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?”
🚨 Super cool quote from the Cybercab breakdown on the decision to avoid traditional paint:
“One of the most expensive parts of the factory is a paint line… a few hundred million dollars, a million man hours to build one… rule number one at Tesla, question the requirements. Why do you need paint?… the alloys we use in the castings… don’t oxidize and reduce strength over time.” -@larsmoravy
Model Y and Cybertruck bodies are fully coated and painted. On Cybercab, only the side pieces get the anti-corrosion dip coat, and there’s no paint shop at all, which helps cut factory floor space per car by about 50%.
— TESLARATI (@Teslarati) October 26, 2026
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.
Tesla’s Cybercab battery design could make robotaxis even cheaper
Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says
