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SpaceX’s NASA astronaut launch debut jumps its place in line, now up next

Barring surprises, SpaceX's next launch will be the company's first NASA astronaut launch ever. (Richard Angle)

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According to NASASpaceflight.com reporter Michael Baylor, SpaceX’s Starlink-7 satellite launch has been indefinitely delayed due to drone ship constraints, meaning that the company’s Crew Dragon astronaut launch is now up next.

As a result, SpaceX’s next orbital launch has been delayed by at least eight days. In return, however, that launch will arguably be the most important in the company’s 18-year history, (hopefully) marking the biggest step by far SpaceX has taken towards its main goals of democratizing spaceflight and enabling the sustainable, permanent settlement of Mars. Known as Demonstration Mission 2 (Demo-2), it will simultaneously be the first crewed launch under NASA’s Commercial Crew Program (CCP) and SpaceX’s first astronaut launch ever and is scheduled to lift off no earlier than (NET) 4:33 pm EDT (20:33 UTC), May 27th.

Formerly scheduled to launch no earlier than (NET) May 7th, 17th, 18th, and 19th after a number of technical and weather-related delays, SpaceX’s 8th 60-satellite Starlink launch has now been delayed until sometime after Crew Dragon’s late-May inaugural astronaut launch. According to NASASpaceflight and speculated about in-depth on unofficial forums in the days prior, the schedule swap decision was made due to constraints in SpaceX’s drone ship. While simple on the face of things, the change does reveal a bit of the hidden strategy behind SpaceX’s management of both its rocket fleet and the ships that recover them.

SpaceX’s next launch may well be the company’s NASA astronaut launch debut. (SpaceX)

Compounded by multiple largely unrelated delays, including weather in the planned booster and fairing landing zones, the Starlink-7/Demo-2 launch swap was caused by the simple fact that SpaceX only has one operational drone ship on the East Coast. The company coincidentally began sea trials with a second drone ship the very same day that Of Course I Still Love You (OCISLY) headed out to sea to catch Starlink-7’s Falcon 9 booster. However, that second ship has been extensively upgraded and will likely take several weeks of sea trials before it can be declared ready for its first East Coast rocket recovery attempt.

B1048 landed for the first time on drone ship Just Read The Instructions (JRTI) on July 27th. (Pauline Acalin)
Pictured here in June 2019, drone ship Just Read The Instructions (JRTI) looks almost completely different ~12 months later. (Pauline Acalin)

For each drone ship booster landing, it takes at least a week for the ship to be towed several hundred miles downrange to the recovery zone and at least as long to return to port. Add in the time required to safe and secure a landed Falcon 9 or Heavy booster, navigate sea states to prevent damage to – or the outright loss of – that booster, and the work needed to safely lift it off the drone ship’s deck onto dry land and it can easily be 9-10 days before a drone ship is ready for another landing.

At the same time, SpaceX’s turnaround record is about eight days between booster landings. Had SpaceX persevered and attempted to launch Starlink-7 on May 19th and Crew Dragon’s inaugural astronaut launch on May 27th, it’s possible that things would have worked out, with both booster landings occurring on schedule on the same drone ship. However, given just how much of a priority Crew Dragon Demo-2 is compared to an internal Starlink launch and a tropical storm threatening to delay Starlink-7’s launch and landing even further, SpaceX clearly decided that it just wasn’t worth the risk.

60 Starlink satellites depart Falcon 9’s second stage. (SpaceX)
Crew Dragon capsule C206 is nearly ready for SpaceX’s inaugural astronaut launch. (SpaceX)

Given the extraordinary importance of Demo-2, set to be the first time the United States has launched its own astronauts into orbit in almost nine years, it’s not exactly surprising that SpaceX has chosen conservatism this time around and prioritized its inaugural NASA astronaut launch. According to Spaceflight Now, the Crew Dragon capsule assigned to SpaceX’s inaugural NASA astronaut launch – pictured above – actually joined the new Falcon 9 rocket that will launch it at Pad 39A on May 15th. Now fully fueled with liquid hydrazine and nitrogen tetroxide, the spacecraft could be mated with Falcon 9’s upper stage at any moment (if it hasn’t been already).

Once fully assembled, Falcon 9 booster B1058, a new Falcon 9 upper stage, Crew Dragon capsule C206, and an expendable trunk section will be rolled horizontally out to Kennedy Space Center (KSC) Pad 39A to perform a crucial pre-launch static fire test. Rollout and static fire operations could begin at any point within the next few days. It remains to be seen whether drone ship OCISLY will remain in the Atlantic Ocean or head back to Port Canaveral before departing again to catch booster B1058.

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 Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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Elon Musk

SpaceX has solved Starship’s biggest challenge, Elon Musk says

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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