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SpaceX, NASA hold press conference, historic astronaut launch clears final hurdles before readiness

The SpaceX Crew Dragon capsule of the Demonstration 1 Mission in March of 2019 is pictured in a SpaceX hangar prior to rolling to the launchpad ahead of launch. (SpaceX)

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With less than a month to go before the historic first crewed flight – and final human rating certification test – of the SpaceX Crew Dragon Demonstration 2 mission, NASA and SpaceX jointly held a full day of pre-mission press conferences on Friday, May 1st. Throughout the day many minor, but crucial, details were revealed.

Two primary technical concerns remained prior to Crew Dragon’s debut astronaut mission- the final drop test of the Crew Dragon Mark III parachutes and NASA’s clearance of SpaceX’s resolution of an in-flight engine-out anomaly suffered during the ascent phase of a previous Starlink mission.

Falcon 9 B1048 is pictured during launch, one frame (~0.05s) before it suffered an engine failure. (SpaceX)

Falcon 9 Merlin 1D engine-out anomaly

During the March 18th Starlink launch of a four-time flown Falcon 9 first-stage booster, a brief anomalous engine flare was witnessed during the ascent. Although ultimately successful in the deployment of the stack of 60 satellites, the first-stage booster failed to stick the landing aboard the autonomous spaceport drone ship “Of Course I Still Love You” resulting in a total loss. SpaceX CEO, Elon Musk, responded to comments posted to Twitter confirming the in-flight, early shutdown anomaly of one of the nine Merlin 1D engines.

Musk provided assurance that a thorough investigation would be conducted by SpaceX prior to any return to flight. Musk also noted that the first-ever engine failure of a Merlin 1D engine proved its robustness and the importance of redundancy provided by the other eight engines.

Just prior to the next Starlink mission on April 22nd marking a recycled Falcon 9 booster’s return to flight, Musk once again took to Twitter to provide insight into the early shutdown, in-flight anomaly. Musk stated that a small amount of isopropyl alcohol, used for cleaning the Merlin 1D engines, had been trapped in a sensor dead leg – later clarified as “an area it couldn’t float through” by SpaceX webcast host Lauren Lyons – and was ignited during flight causing the early shutdown of one Merlin 1D engine.

As identified during the April 22nd launch broadcast, out of an abundance of caution SpaceX decided to forgo that cleaning process for the April 22nd mission. However, no information was divulged regarding NASA’s response to either the anomaly or the resolution. Ultimately, the first stage Falcon 9 booster of the Starlink-6 performed flawlessly and even managed to stick the landing aboard the awaiting drone ship.

During Friday’s Commercial Crew and International Space Station overview news conference, a question regarding NASA’s response to the anomaly posed by Jeff Foust – reporter for SpaceNews.com – was directed to NASA’s Commercial Crew Program program manager, Kathy Lueders. She was asked to expand on the final technical constraints remaining prior to the launch of the Crew Dragon DM-2. Lueders responded positively stating that NASA had “reviewed the anomaly resolution…and cleared the engines on our launch vehicle” referring to the Falcon 9 booster slated to support DM-2, noting that the engine-out issue had been satisfactorily resolved and is now behind them.

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One more drop test

Early in Friday’s Commercial Crew and International Space Station overview news conference – and later confirmed during remarks made by Lueders – SpaceX Chief Operating Officer, Gwynne Shotwell noted that a final 27th drop test of the Crew Dragon Mk III parachutes was scheduled to be completed later in the day. During a later Q&A interview with the crew of DM-2 – NASA astronauts Bob Behnken and Doug Hurley – Hurley commented that the final drop test had begun, however, he wasn’t quite sure if it had been completed successfully or not.

Just after the closing remarks of the crew Q&A interview, SpaceX announced via social media the successful completion of the 27th and final drop test of the all-important Mk III parachutes.

The May 1st final parachute drop test followed a worrisome stumble of the parachute program on March 24th. SpaceX announced that a Crew Dragon test article had become unstable forcing the helicopter pilot to prematurely release the test article out of an abundance of caution to maintain the safety of the helicopter crew. SpaceX noted that “while the test article was lost, this was not a failure of the parachute system and most importantly no one was injured.”

The confirmation of the successful May 1st drop test and the resolution of the Merlin 1D engine anomaly close out one of the final chapters of prerequisites prior to returning human spaceflight to American soil.

The only hurdles that remain to be cleared are various agency-level readiness reviews. According to Lueders, a SpaceX Flight Readiness Review is tentatively scheduled for Friday, May 8th followed by a NASA Flight Readiness Review on May 11th. Just one week ahead of launch, the final joint Launch Readiness Review is tentatively scheduled to be completed Wednesday, May 20th at which point DM-2 will bring crewed astronaut spaceflight back to American soil for the first time in nearly a decade.

Check out Teslarati’s newsletters for prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket launch and recovery processes.

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Tesla shows what Roadster drivers will see on screen before thruster activation

Tesla’s Roadster video reveals a fighter jet inspired cockpit with a 5,500 PSI thruster gauge.

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The next generation Tesla Roadster’s touchscreen, shown in Tesla’s first official look at the car’s interface. (Credit: Tesla/X)

Tesla has given future owners their clearest look yet at the cockpit of its next generation Roadster. In a 34 second video posted to X on Friday afternoon, the company walked through the car’s touchscreen with a caption: “Inspired by fighter jet cockpits, Roadster’s interface was designed around the pilot.”

The clip opens on a black screen with red graphics and a 3D wireframe of the car, which sits beside the Roadster’s squared off yoke. Tapping parts of the model brings up controls for the rear wing, including low drag and high downforce positions, along with a charging page with a charge limit bar and a small music player. A row of tabs along the bottom reads Home, Vehicle, Listen, Climate and Navigate.

Most of the video is spent in Track Mode. The dashboard shows a live circuit map, a list of session lap times, brake and motor temperatures, and pressure and temperature readouts for each tire. A setup page lets the driver pick Auto, Low Drag, High Downforce or Custom aero modes, adjust aero balance and brake balance, and switch stability and traction control off. Along the bottom, a status bar reads “Thruster · 5,500 PSI” next to a “Boost Ready” indicator.

That gauge ties the software to the hardware Tesla showed off near Waco, Texas on October 15. The Thrust and Rocket versions use cold gas thrusters fed by carbon overwrapped pressure vessels, and Tesla lists 0 to 60 mph times of under 0.9 seconds and under 0.59 seconds for them, as Teslarati detailed in its breakdown of the three Roadster configurations. The base Performance car relies on a fan and ground sealing system for grip, and the aero settings on screen match the active wings and suction setup covered in our look at how the Roadster generates downforce.

The Roadster layout is a departure from the rest of Tesla’s lineup. Instead of a map centered screen, the Roadster puts the car itself at the center of the home page, and Tesla’s Roadster page lists two smaller forward displays alongside the main touchscreen. Tesla has not said whether any of the Track Mode telemetry will make its way to the Model 3 Performance or other vehicles.

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The interface could still change before deliveries. Elon Musk said at the event that Roadster production will begin in 2028, and Tesla says the flagship Rocket version is not approved for public road use. Reservations are open with a $50,000 payment, while Thrust is listed as a limited release and Rocket is invite only.

Those who want to see the car in person will get their first chance this weekend. The Roadster goes on display in the lobby of the Petersen Automotive Museum in Los Angeles from October 24 to 27, according to Sawyer Merritt, the first time the public will be able to view it up close.

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Tesla reveals Optimus Academy, where robots teach themselves

Tesla has begun building production quality Optimus robots in Fremont and revealed its training plan.

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Concept rendering of Tesla Optimus in mass production

Tesla has started building Optimus on the high volume line it set up inside its Fremont factory, and the company says the robots coming off it are the first that meet the bar for a real product. “The bots coming off this line are the first production-quality bots that we have manufactured,” Tesla wrote in its third quarter shareholder letter, adding that it has “proven that the current manufacturing process for Optimus is suitable for a commercial product.”

The line sits in space that built the Model S and Model X until this spring. Tesla cleared the old vehicle line in 46 days, as Teslarati reported in July, to make room for robot production sized for one million units a year. On Wednesday’s earnings call, Elon Musk said most of the equipment for that capacity is already in Fremont, with output set to climb toward roughly 20,000 robots a week as the line ramps.

Musk described the ramp as a classic S curve. “The growth of Optimus is an S curve, but the initial curve is a shallow slope,” he said. The team is now refining the robot’s AI, electromechanical design, reliability and service life, and Musk expects that work to be finished by the end of next year, when Tesla plans to start delivering Optimus to outside companies for dangerous, repetitive and around the clock jobs.

The most interesting part of the call was how Tesla plans to teach the robots. Its cars send real driving data back to the AI team from millions of vehicles, but Optimus has no fleet like that yet. “A big difference with Optimus versus the cars is we don’t have this vast fleet of cars from which we can gather training data,” Musk said. Tesla’s answer is an Optimus Academy, where 10,000 to 20,000 robots will practice a wide range of tasks and feed what they learn into the next version of the model. Every unit off the Fremont line becomes a source of that training data.

Smarter hardware is on the way too. Tesla plans to put its AI5 chip into Optimus next year, and Musk said a new Optimus video should arrive within one or two months showing the robot completing tasks driven by AI rather than preprogrammed motions. He took aim at rival humanoid demos that only run scripted routines, saying those would not hold up in the real world.

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The supply chain is lining up behind the program. In September, Tesla certified Tuopu, Joyson and Sanhua as mass production partners for Optimus components. A far larger Optimus factory is also rising at Giga Texas, where drone footage from Joe Tegtmeyer showed the steel frame nearing completion, and Musk has pegged that plant’s long term target at 10 million robots a year.

Tesla executives also said Optimus production costs are trending toward the expected manufacturing cost of Cybercab, a sign the robot is being engineered for volume from the start. The hands remain the toughest piece of the design, a point Musk also made at the X Takeover event earlier this month, as Teslarati covered at the time, and that is where much of the current engineering effort is focused.

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The Starship moon landing number NASA and Elon Musk can’t agree on

Musk disputes NASA estimate of 22 Starship launches for Moon landing, predicting 6 to 8.

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Concept rendering of SpaceX Starship landing on the moon via Grok

Elon Musk is disputing a new NASA safety panel estimate of how many Starship launches it will take to put astronauts on the Moon, saying the real number will be less than half the panel’s figure.

On Thursday, NASA’s Aerospace Safety Advisory Panel held its quarterly public meeting. Panel member Charlie Precourt, a former NASA astronaut, flagged the fueling process for SpaceX’s lunar lander as a major risk for Artemis IV, the mission planned to land a crew on the Moon in 2028. “We need to keep our eyes on numerous required fuelings for the lander,” Precourt said, according to Ars Technica. “I think the last estimate is around 22 flights.”

Ars Technica’s Eric Berger posted the comment on X, and Musk replied. “That’s way too high,” Musk wrote. “Actual number will be more like 6 to 8.”

The disagreement comes down to a basic problem with sending a ship as large as Starship to the Moon. Starship burns nearly all of its propellant just reaching Earth orbit, so it cannot continue on to the Moon without stopping for a refill. SpaceX’s answer is a gas station in space. First, a Starship that works as a storage tank, called a depot, is launched into orbit. Then a series of tanker Starships launch one at a time, dock with the depot and pump their leftover propellant into it. Once the depot is full, the lunar lander version of Starship launches, docks, fills up and heads for the Moon.

Every tanker trip is its own full rocket launch, which is why the count matters. More launches mean more time, more cost and more chances for something to go wrong before astronauts ever leave Earth. Berger estimated that even if SpaceX reaches twice weekly Starship launches by the end of 2027, filling a depot at the panel’s number would still take roughly three months.

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How many tankers are needed depends mostly on how much propellant each one can carry to orbit and how much is lost along the way. Starship’s fuel and oxygen are stored at extremely cold temperatures, and some of it slowly boils off while waiting in orbit. More is lost in each transfer. NASA appears to be working from what Starship can lift today, while Musk’s range assumes a more capable rocket.

Musk has pushed back on higher counts before. In 2021, after a government document suggested 16 launches, he called that “extremely unlikely” and said eight tankers would be the most required.

Much of the answer depends on hardware SpaceX has not finished flying. As Teslarati noted earlier this year, the company plans to carry out the refueling process with its upgraded V3 Starship, and Precourt described Artemis IV as carrying “a large number of firsts.” He also praised NASA Administrator Jared Isaacman’s team for working to clear obstacles for both SpaceX and Blue Origin, whose Blue Moon lander does not rely on orbital refueling for its first mission.

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