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SpaceX's first NASA astronaut launch closer than ever as spacecraft and rocket near Florida

Crew Dragon arrived at the International Space Station on March 3rd, 2019 during Demo-1, its inaugural orbital launch. (NASA/Oleg Kononenko)

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According to an engineer’s February presentation, SpaceX is on the brink of shipping its first NASA astronaut-rated Crew Dragon spacecraft to Kennedy Space Center – arguably the company’s biggest milestone yet on the path to human spaceflight.

In the last year, SpaceX’s Crew Dragon program has undeniably stumbled a few times, suffering challenging parachute failures and the catastrophic explosion of the first flight-proven Crew Dragon capsule. However, the year has been filled with far more successes. By all appearances, Crew Dragon’s parachute issues have been completely solved, while SpaceX successfully static fired an upgraded Crew Dragon’s SuperDraco engines before launching a flawless in-flight abort (IFA) test just last month.

Prior to all of this, SpaceX’s Crew Dragon spacecraft completed what NASA deemed a “flawless” and “phenomenal” orbital launch debut, docking with and departing the space station without issue before safely reentering Earth’s atmosphere and splashing down in the Atlantic Ocean. Now, ten months after that flawless debut, SpaceX is perhaps just a week or two away from reaching a major milestone ahead of its first NASA astronaut launch.

In just a few short months, this scene could be repeated – but with NASA astronauts at Crew Dragon’s helm. (NASA)

Part of some kind of Kennedy Space Center (KSC) event on February 1st or 2nd, SpaceX Director of Vehicle Integration Christopher Couluris gave an exceptionally insightful presentation that was apparently recorded and (very) briefly available on YouTube. Aside from a great deal of new and useful information on Falcon booster reusability, Starship manufacturing, and more, Couluris also teased some major news for SpaceX’s Crew Dragon spacecraft.

SpaceX has finally set the date for Crew Dragon's In-Flight Abort test. (Teslarati - Pauline Acalin)
Excluding Falcon 9, all pieces of SpaceX’s first astronaut-rated Crew Dragon spacecraft are visible in this one frame. (Teslarati – Pauline Acalin)
Assigned to Crew Dragon’s Demo-2 astronaut launch debut, SpaceX Falcon 9 booster B1058 successfully completed a routine static fire test back in August 2019. (SpaceX)

In short, Couluris revealed that the Crew Dragon spacecraft – capsule C206 and an expendable trunk – assigned to SpaceX’s ‘Demo-2’ NASA astronaut launch debut could arrive at the company’s Florida Dragon processing facilities as early as mid-February, just a week or two from now. At the same time, comments the SpaceX engineer made about the number of SpaceX rocket boosters currently in Florida heavily implied that the Falcon 9 rocket assigned to said astronaut launch debut is already at KSC Launch Complex 39A (or at least nearby).

In other words, after Crew Dragon arrives, SpaceX will have all the hardware on hand and ready for its first NASA astronaut launch – arguably the single most important mission in the company’s history. Barring calamity, all that will remain is a few weeks of processing and an indeterminately long period of NASA/SpaceX reviews and paperwork. Elon Musk recently stated that he was confident that Crew Dragon Demo-2 would be fully ready to launch as early as April 2020, although May or June are also a strong possibility.

Falcon 9 and Crew Dragon stand vertical at Pad 39A for the second time ever on January 17th, 2020. (Richard Angle)

Funded by NASA and designed and built by SpaceX, Crew Dragon (Dragon 2) is an upgraded version of the company’s workhorse Cargo Dragon (Dragon 1) spacecraft, which has successfully performed 18 International Space Station (ISS) resupply missions in just eight years. While there’s a chance that SpaceX will ultimately use Crew Dragon for its own needs, like private orbital tourism, the spacecraft’s primary purpose is to routinely carry NASA astronauts to and from the Space Station – a capability the US has not had since NASA and Congress prematurely killed the Space Shuttle in 2011.

SpaceX’s Crew Dragon spacecraft – along with Boeing’s delayed Starliner – is intended to fill a void the Space Shuttle left in 2011. (Richard Angle)

Originally intended to launch as early as 2017, both SpaceX and Boeing suffered major delays as they worked through the many challenges associated with human spaceflight and grappled with several years of egregious Congressional underfunding.

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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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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.

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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.

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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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