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SpaceX’s NASA Crew Dragon launch manifest doubles in three months
NASA says it will soon award SpaceX another five Crew Dragon astronaut transport contracts after purchasing three extra missions from the company on February 28th.
That June 1st announcement means that NASA has more than doubled the number of operational Crew Dragon astronaut launches planned between 2020 to the end of 2030 in the last three months – a decision that represents another major SpaceX upset over Boeing. In reality, NASA has simply made some cold and rational calculations about its two Commercial Crew providers and – with no ill intent – made far-reaching decisions to preemptively secure its astronauts’ access to the International Space Station (ISS) for the rest of this decade. Intentional or not, however, the optics of those decisions speak volumes.
When NASA awarded Boeing and SpaceX their original $4.2 billion and $2.6 billion Commercial Crew Transportation Capability (CCtCap) contracts in 2014, the agency’s goal (or hope) was for both providers to complete the development of their Starliner and Crew Dragon spacecraft in roughly the same amount of time. Boeing and SpaceX would have then taken turns, each performing one six-month crew transportation mission per year and ensuring redundant access to the ISS for the rest of its life.
More realistically, the general assumption was that Boeing – an ancient aerospace company with half a century of spaceflight experience – would smoothly complete Starliner while SpaceX – a 12-year-old startup – would struggle to push Crew Dragon across the finish line. Of course, exactly the opposite proved to be true. For what would ultimately become (to NASA) $3.15 billion to Boeing’s $4.95 billion and development and test flight costs of $1.2 billion to Boeing’s $2.2 billion, SpaceX completed its first successful uncrewed and crewed Crew Dragon test flights in March 2019 and May 2020. In contrast, Boeing’s first uncrewed Starliner launch attempt nearly ended in catastrophe in December 2019. A second July 2021 attempt at that mission was prevented from launching by unrelated technical difficulties. Only on May 25th, 2022 did Boeing finally complete the equivalent of Crew Dragon’s March 2019 Demo-1 test flight.
NASA’s February 28th purchase of three more SpaceX Crew Dragon missions was unsurprising. The future of Starliner was still unclear and the Dragon missions it was purchasing could be needed as early as 2023 if Boeing’s spacecraft was not ready in time. The timing of NASA’s notice of intent to purchase another five Crew Dragon missions one week after the end of Boeing’s mostly successful OFT-2 test flight, however, is somewhat surprising. Instead of throwing Boeing a bone after its long-awaited success and somewhat balancing the scales between its two Commercial Crew providers, NASA has ultimately decided to purchase more than twice as many crew missions from SpaceX.
Following NASA and SpaceX’s successful Crew-4 launch last month, the space agency needs 16 more six-month transport missions from SpaceX and Boeing to ensure astronaut access to the ISS between now and late 2030. NASA has issued its intent to perform up to 14 operational Crew Dragon missions and up to 6 Starliner missions (via Boeing’s original contract). Subtracting the 4 missions SpaceX has completed or is in the midst of completing, NASA will soon have all the contracts it needs to crew the ISS until the end of 2030 without purchasing a single extra mission from Boeing.
As a result, barring surprises, SpaceX will likely be responsible for launching 70% of all NASA and ESA astronauts from late 2020 to the end of 2030, while Boeing will be tasked with carrying the remaining 30%. A less likely Commercial Crew outcome would have been hard to imagine in 2014.
News
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
The suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Tesla has confirmed that it is now producing both the anode and cathode of its 4680 battery cells using a dry-electrode process, marking a key breakthrough in a technology the company has been working to industrialize for years.
The update, disclosed in Tesla’s Q4 and FY 2025 update letter, suggests the company has finally resolved one of the most challenging aspects of its next-generation battery cells.
Dry cathode 4680 cells
In its Q4 and FY 2025 update letter, Tesla stated that it is now producing 4680 cells whose anode and cathode were produced during the dry electrode process. The confirmation addresses long-standing questions around whether Tesla could bring its dry cathode process into sustained production.
The disclosure was highlighted on X by Bonne Eggleston, Tesla’s Vice President of 4680 batteries, who wrote that “both electrodes use our dry process.”
Tesla first introduced the dry-electrode concept during its Battery Day presentation in 2020, pitching it as a way to simplify production, reduce factory footprint, lower costs, and improve energy density. While Tesla has been producing 4680 cells for some time, the company had previously relied on more conventional approaches for parts of the process, leading to questions about whether a full dry-electrode process could even be achieved.
4680 packs for Model Y
Tesla also revealed in its Q4 and FY 2025 Update Letter that it has begun producing battery packs for certain Model Y vehicles using its in-house 4680 cells. As per Tesla:Â
“We have begun to produce battery packs for certain Model Ys with our 4680 cells, unlocking an additional vector of supply to help navigate increasingly complex supply chain challenges caused by trade barriers and tariff risks.”
The timing is notable. With Tesla preparing to wind down Model S and Model X production, the Model Y and Model 3 are expected to account for an even larger share of the company’s vehicle output. Ensuring that the Model Y can be equipped with domestically produced 4680 battery packs gives Tesla greater flexibility to maintain production volumes in the United States, even as global battery supply chains face increasing complexity.
Elon Musk
Tesla Giga Texas to feature massive Optimus V4 production line
This suggests that while the first Optimus line will be set up in the Fremont Factory, the real ramp of Optimus’ production will happen in Giga Texas.
Tesla will build Optimus 4 in Giga Texas, and its production line will be massive. This was, at least, as per recent comments by CEO Elon Musk on social media platform X.
Optimus 4 production
In response to a post on X which expressed surprise that Optimus will be produced in California, Musk stated that “Optimus 4 will be built in Texas at much higher volume.” This suggests that while the first Optimus line will be set up in the Fremont Factory, and while the line itself will be capable of producing 1 million humanoid robots per year, the real ramp of Optimus’ production will happen in Giga Texas.Â
This was not the first time that Elon Musk shared his plans for Optimus’ production at Gigafactory Texas. During the 2025 Annual Shareholder Meeting, he stated that Giga Texas’ Optimus line will produce 10 million units of the humanoid robot per year. He did not, however, state at the time that Giga Texas would produce Optimus V4.Â
“So we’re going to launch on the fastest production ramp of any product of any large complex manufactured product ever, starting with building a one-million-unit production line in Fremont. And that’s Line one. And then a ten million unit per year production line here,” Musk stated.Â
How big Optimus could become
During Tesla’s Q4 and FY 2025 earnings call, Musk offered additional context on the potential of Optimus. While he stated that the ramp of Optimus’ production will be deliberate at first, the humanoid robot itself will have the potential to change the world.Â
“Optimus really will be a general-purpose robot that can learn by observing human behavior. You can demonstrate a task or verbally describe a task or show it a task. Even show it a video, it will be able to do that task. It’s going to be a very capable robot. I think long-term Optimus will have a very significant impact on the US GDP.
“It will actually move the needle on US GDP significantly. In conclusion, there are still many who doubt our ambitions for creating amazing abundance. We are confident it can be done, and we are making the right moves technologically to ensure that it does. Tesla, Inc. has never been a company to shy away from solving the hardest problems,” Musk stated.
Elon Musk
Rumored SpaceX-xAI merger gets apparent confirmation from Elon Musk
The comment follows reports that the rocket maker is weighing a transaction that could further consolidate Musk’s space and AI ventures.
Elon Musk appeared to confirm reports that SpaceX is exploring a potential merger with artificial intelligence startup xAI by responding positively to a post about the reported transaction on X.
Musk’s comment follows reports that the rocket maker is weighing a transaction that could further consolidate his space and AI ventures.
SpaceX xAI merger
As per a recent Reuters report, SpaceX has held discussions about merging with xAI, with the proposed structure potentially involving an exchange of xAI shares for SpaceX stock. The value, structure, and timing of any deal have not been finalized, and no agreement has been signed.
Musk appeared to acknowledge the report in a brief reply on X, responding “Yeah” to a post that described SpaceX as a future “Dyson Swarm company.” The comment references a Dyson Swarm, a sci-fi megastructure concept that consists of a massive network of satellites or structures that orbit a celestial body to harness its energy.Â
Reuters noted that two entities were formed in Nevada on January 21 to facilitate a potential transaction for the possible SpaceX-xAI merger. The discussions remain ongoing, and a transaction is not yet guaranteed, however.
AI and space infrastructure
A potential merger with xAI would align with Musk’s stated strategy of integrating artificial intelligence development with space-based systems. Musk has previously said that space-based infrastructure could support large-scale computing by leveraging continuous solar energy, an approach he has framed as economically scalable over time.
xAI already has operational ties to Musk’s other companies. The startup develops Grok, a large language model that holds a U.S. Department of Defense contract valued at up to $200 million. AI also plays a central role in SpaceX’s Starlink and Starshield satellite programs, which rely on automation and machine learning for network management and national security applications.
Musk has previously consolidated his businesses through share-based transactions, including Tesla’s acquisition of SolarCity in 2016 and xAI’s acquisition of X last year. Bloomberg has also claimed that Musk is considering a merger between SpaceX and Tesla in the future.
Tesla confirms that it finally solved its 4680 battery’s dry cathode process
Tesla Giga Texas to feature massive Optimus V4 production line
