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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 Optimus Gen 3 shows off a cleaner, factory-ready design in new app discovery

Renders hidden inside Tesla’s Android app show Optimus Gen 3’s design before any official reveal.

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla may have accidentally given a first look at its newest Optimus Gen 3 humanoid robot when photos were found in the Tesla smartphone app.

Design files tucked inside a recent Android version of the Tesla app appear to show the third generation humanoid robot next to the older Gen 2.5 prototype. The assets were extracted from the app package by Tesla community member @wholemars, who posted the renders on X late Tuesday night before deleting them. The Tesla Newswire reshared the side by side comparison on Wednesday, and the images have circulated widely since.

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

The files are labeled “gen3” and were built as models for Tesla app’s own interface, as validated directly by Grok to be official.

The comparison shows a robot that looks built for a factory line rather than a lab bench. Gen 2.5’s exposed mechanical linkages and gold plating on the knees and shins are gone. In their place, Gen 3 uses matte black fairings on the lower legs, paired with a more contoured champagne gold body. Flexible covers now seal the joint where the torso meets the upper thighs, keeping bearings and moving parts sealed from debris and unnecessary contact.

The body panels fit more tightly, and the hands, which Tesla has said carry 22 degrees of freedom, look far more refined than those on earlier units.

This most recent leak fills a gap Tesla has left open for most of the year. Elon Musk said on March 31 that Optimus 3 was walking around but needed “some finishing touches” before it could be shown, a delay Teslarati covered when Tesla missed its first quarter reveal target. Musk later said Tesla would hold the design back until closer to production, partly to keep competitors from copying it. No reveal date has been announced.

The app itself has been preparing for Optimus for months. In July, code in the Tesla app pointed to a dedicated robot phone key, a consent screen for collecting video and spatial data while Optimus works inside a home, and an alert system for low battery and mechanical faults. Finished 3D models of Gen 3 suggest the interface owners will eventually use is moving past placeholder code toward something Tesla intends to ship.

Manufacturing is moving in parallel. Tesla tore out the original Model S and Model X lines at Fremont this summer to make room for Optimus production, with a planned capacity of one million robots a year. At Giga Texas, the steel frame of a dedicated Optimus factory is nearing completion ahead of a targeted 2027 start, with Musk pointing to an eventual output of 10 million units annually.

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Tesla Semi lands the biggest electric truck deal in U.S. history

Tesla leads a record 2,500 truck order, but not every truck will be a Semi.

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Tesla has landed the largest electric truck order in U.S. history. ZET SCALE, a new alliance of shippers and carriers, named Tesla its primary manufacturer on Tuesday for an initial order of 2,500 electric Class 8 trucks. The deal alone would nearly double the number of electric heavy trucks operating in the country.

According to the press release from Catalyst Mobility, the nonprofit formerly known as CALSTART, Kenworth, RIDE and Volvo were also selected as secondary manufacturers that carriers can pick if their operations call for it. No split between the four brands has been published, so the exact number of Semis in the order is not yet known.

Tesla won the top slot through a competitive request for proposals. The alliance, which Catalyst Mobility runs with the Smart Freight Centre, scored bidders on price, range, charging capability and production capacity. Pooling freight demand from founding shippers, including Microsoft and PepsiCo, let every truck maker bid lower than it would for a single fleet. “The Tesla Semi is designed for lower cost per mile operations than diesel,” said Dan Priestley, director of the Tesla Semi program, as noted in the press release.

The financing is built to pull in carriers who have avoided electric trucks. ZET Financial is issuing the purchase order for all 2,500 units and will place them with fleets through a fair market value lease. The trucks will be deployed over the next few years across 10 freight hubs in Los Angeles, Stockton, Bakersfield, Seattle and Tacoma, Houston, Dallas, San Antonio, Chicago, Atlanta, and the Newark and New York area. ZET SCALE says the first order is only the opening round, with a longer term goal of 10,000 trucks or more.

Even if Tesla ends up with only a majority share, it would still be the biggest Semi deal to date. Einride’s 500 unit order in August was the previous record, and WattEV’s 370 truck order in May was the largest California deal at the time. Einride’s CEO has since said he expects all 500 trucks delivered by the end of 2027.

The announcement lands two days before Tesla formally inaugurates its Semi factory in Nevada on September 24. The 1.7 million square foot plant sits next to Gigafactory Nevada’s 4680 cell lines and is designed for 50,000 trucks a year.

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Tesla integrates Grok Bot into its vehicles for the ultimate personal assistant

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Credit: Grok

Tesla has expanded Grok from an in-car chatbot into a hands-free work assistant. On September 22, Tesla officially launched Grok Bot capability, confirming that drivers can now manage email, calendars, files, chats, and tasks by voice and then hand more ambitious errands to the AI-fueled productivity cheat code.

Grok itself is built by xAI. The new car features split into two layers: Connectors link Grok to outside accounts. Grok Bot, currently limited to SuperGrok Heavy subscribers, can complete multi-step tasks such as placing a usual coffee order, booking a reservation, or scheduling an appointment. It truly puts the driver in a nearly complete hands-free driving and productivity setting, with ironically the only task truly requiring your hands being to touch the “Start Self-Driving” button.

We were granted access to Grok Bot’s Tesla integration a few weeks back, and we’ve been able to do a handful of things with it. On a handful of occasions, we’ve used it to order food and have it ready for pickup slightly later into the evening; we’ve managed to pick up groceries after a day of errands with Grok Bot, and outside of the car, it’s helped with budgeting and even my fantasy football draft.

Tesla shows another way to utilize it: in their demo, a driver says “Hey Grok,” asks the assistant to check an inbox, and hears that a message concerns a weekend reservation. Grok then scans the calendar, reports no conflicts, and confirms the Tahoe trip is clear. It can also add check-in details to a road-trip itinerary. The point is not novelty chat. It is keeping eyes on the road, or on Full Self-Driving, while the car handles the paperwork of a trip:

This Grok rollout is not a gadget add-on as much as it is Tesla’s thesis in software form: the car should stop being a machine you operate and start being a room you occupy.

Connectors and Grok Bot treat the cabin as an office that happens to move, and that has truly been Tesla’s intention for years now. The car has slowly become an extension of a home more than a vehicle. Inbox, calendar, groceries, takeout, and reservations become voice work, not dashboard chores that you need to do before you get in your car.

Responsibility shifts from the driver to the stack, and as many Tesla owners rely on FSD for travel, Grok Bot now handles the monotony of dinner reservations or appointments.

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