News
SpaceX rapidly tests, ships Falcon 9 second stage for next NASA astronaut launch
SpaceX has shipped, tested, and delivered the new Falcon 9 upper stage tasked with carrying the company’s next Crew Dragon astronauts to orbit as early as October 30th.
Offering rare insight into the kind of timelines and margins SpaceX operates on for even its most important missions, a Falcon upper stage bearing NASA’s ‘worm’ logo and ‘meatball’ insignia was spotted by a local resident and photographer on October 2nd. Thus far, the only SpaceX rockets that have flown with NASA iconography are those supporting Crew Dragon launches, making them a dead giveaway for Crew Dragon launch hardware.
After Demo-2, SpaceX’s May 2020 astronaut launch debut, the company moved those decals from Falcon 9’s booster – liable to fly any number of non-NASA missions later in life – to each NASA crew mission’s expendable Falcon second stage (S2). Since then, Crew-1 (November 2020) and Crew-2 (April 2021) have both launched with NASA logos on their second stages and Crew-3 now looks set to continue that tradition.
Thanks to the watchful eye of local resident turned SpaceX fan Reagan Beck, it was actually possible to identify Crew-3’s Falcon 9 upper stage as soon as it was spotted at the company’s McGregor, TX development and testing facilities on October 2nd. While there was technically a tiny chance that it could be for one of several upcoming NASA spacecraft launches or even for Crew Dragon’s April 2022 Crew-4 mission, the likeliest destination by far for the NASA-branded Falcon S2 was Crew-3.
Due partially to the fact that Falcon booster qualification testing typically takes McGregor at least two or so weeks but mainly to the seemingly razor-thin schedule margins it would imply, there was some understandable skepticism that the upper stage was bound to launch Crew-3 just four weeks after it was first spotted. Moreso, Crew Dragon typically rolls out to the launch pad on Falcon 9 at least 5-7 days before launch to allow extra time for an integrated static fire, final checkouts, and a ‘dry dress’ practice runs for each mission’s crew.
Further, even after completing static fire qualification testing in McGregor, Crew-3’s Falcon stage would still need to be packaged up, transported more than a thousand miles by road, carefully unpackaged at a SpaceX launch site or hangar, outfitted with a Merlin Vacuum nozzle extension, installed on the mission’s Falcon 9 booster, and mated to Crew Dragon itself before that pad rollout can occur. In other words, rather than Crew-3’s exact October 30th launch date, the mission’s upper stage would likely need to arrive at SpaceX’s Kennedy Space Center (KSC) Pad 39A launch facilities at least 9-10 days before launch.
Realistically, that means that from the moment the NASA-branded upper stage first spotted on a McGregor test stand, it had maybe two weeks to complete qualification testing and ship out to Pad 39A. With practically no context, that seemed like a stretch at the time – particularly for a single-engine Falcon second stage explicitly tasked with safely delivering four astronauts to orbit. In reality, McGregor’s Falcon S2 testing is apparently far faster than booster testing and the presumed Crew-3 stage seemingly passed qualification testing and vacated the test stand less than five days after it was installed.
In theory, that left the McGregor team about a week to complete post-test inspections, clean the interior of its propellant tanks, and prepare the stage for the last leg of its journey to Florida. SpaceX seemingly managed that without issue and a new Falcon upper stage potentially meant for Crew-3 was spotted in Florida just a few miles away from a SpaceX launch site on October 14th.
However, per additional photos and reports from Reagan, McGregor’s second stage test team has been incredibly busy over the last month or so. Prior to the Crew-3 stage’s arrival, another second stage completed qualification testing between September 21st and 28th. Crew-3’s S2 was installed on October 2nd and removed by the 7th. Wasting no time, another second stage was installed on the same stand on October 10th and apparently completed testing by the 13th – equivalent to a new upper stage qualified every week. Even if the Falcon stage that arrived at Cape Canaveral on October 14th isn’t Crew-3’s, then, Crew-3’s can’t be far behind.
Ultimately, SpaceX appears to be testing and shipping one of two integral Falcon 9 stages for a crucial, schedule-sensitive NASA astronaut launch with schedule margins measured in hours or single-digit days. That’s a far cry from competitors Arianespace and ULA and even NASA itself, which generally deliver flight hardware months in advance. Eleven years since Falcon 9’s launch debut, every Falcon second stage that has made it through stage separation – 127 of 127 – has successfully ignited its Merlin Vacuum engine one or several times and delivered its payload(s) to the correct orbit(s). Well over half of those successful launches were completed in the last three and a half years – and with the same Falcon 9 upper stage variant now routinely tasked with carrying astronauts to orbit.
In other words, delivering a NASA Crew mission’s Falcon second stage less than two weeks before the assembled rocket is scheduled to roll out to the launch pad may seem a tad reckless, it’s more likely that it’s evidence of SpaceX’s second stage build/test teams and facilities operating as an incredibly reliable, well-oiled machine.
Elon Musk
SpaceX to become America’s Military data backbone for missiles, drones, and warfighters
The Space Force just handed SpaceX $2.29 billion to build the military’s space internet backbone.
The U.S. Space Force awarded SpaceX a $2.29 billion contract on May 26, 2026 to build the backbone of its Space Data Network, a satellite-based communications system designed to keep American military forces connected anywhere on Earth in real time. The contract is firm-fixed-price and requires SpaceX to deliver a fully operational prototype by the end of 2027.
In plain terms, the SDN Backbone is the plumbing behind the military’s space-based internet. It functions as a low Earth orbit satellite constellation providing robust, high-capacity, and low-latency data transport for the Joint Force, connecting sensors and weapons systems continuously, globally, and securely. Think of it as a private, hardened version of Starlink built specifically for battlefield communications, one that soldiers, ships, and aircraft can rely on even in contested environments where ground-based networks have been disrupted.
SpaceX is quietly becoming the U.S. Military’s only reliable rocket
The Space Force was direct about why SpaceX was selected. “The SDN Backbone leverages the best of commercial innovation and delivers a strong foundation for the SDN mission set — a huge benefit and enabler for our warfighters,” said USSF Col. Ryan Frazier.
“We aren’t trading speed for scale; we are demanding both. By using rapid prototyping and Other Transaction Authorities, we are ensuring our advanced solutions are integrated and delivered to the warfighter as fast as possible,” added USSF Lt. Col. Fry, SDN Backbone system program manager.
The SDN Backbone will work alongside the Space Development Agency’s Transport Layer, with the two systems forming a unified open architecture to provide critical data transport for current and future Department of War missions.
As Teslarati has reported, this is not SpaceX’s first Space Force contract of 2026. In April, the Space Force awarded SpaceX $178.5 million to launch missile tracking satellites, and SpaceX is already embedded in the Golden Dome missile defense software group. The $2.29 billion SDN Backbone award puts SpaceX at the center of how the American military communicates in space, a position with direct implications for its reported $1.75 trillion IPO valuation as the company heads toward a public offering as early as June 2026.
Tesla’s dedicated factory for building up to ten million Optimus units is officially under construction at Gigafactory Texas.
Drone footage released on May 27 by Giga Texas observer Joe Tegtmeyer captures the significant milestone of the first steel structure officially standing at Tesla’s new Optimus factory on the North Campus of the facility.
Phase two of land reclamation is advancing steadily, and the progress will let the new building extend nearly the full length of the main Giga Texas factory, potentially exceeding 4,000 feet, while measuring somewhere between 50 and 70 meters narrower. Extensive foundation work is proceeding as well.
Big news at the new Optimus 10m/y factory construction site today! The 1st steel structure has been erected & as expected the second phase of land reclamation is underway.
This will allow this new factory to grow to nearly the same length as the main Giga Texas factory,… pic.twitter.com/FidRLV6XpU
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) May 27, 2026
This facility forms a central element of Tesla’s broader North Campus expansion at Giga Texas. The project will add more than 5.2 million square feet of new industrial space. It sits alongside other advanced developments, including a Terafab for next-gen AI chips. The scale reflects Tesla’s commitment to transforming humanoid robotics into a core pillar of the company’s future.
Musk has said that Optimus will be the biggest product in the world on several occasions. He believes it will be Tesla’s biggest valuation contributor.
Tesla prepares to expand Giga Texas with new Optimus production plant
Tesla plans to build about 10 million robots at the site annually once it is completed, which would be about 27,000 units each day.
The Optimus plant at Giga Texas is part of Tesla’s phased strategy for Optimus manufacturing. In an effort to start production of the robot well before the Giga Texas plant is complete, Tesla ended production of the Model S and Model X vehicles, which were built in Fremont, California, to make way for initial Optimus manufacturing efforts.
Production there will start in either July or August of this year, and early units will support internal factory tasks while the team gathers real-world data to refine processes. The Gigafactory Texas facility will house a second-gen production line. It targets high-volume output starting in Summer 2027.
Musk has repeatedly described Optimus as potentially more valuable than Tesla’s entire vehicle business. Current versions are already completing minor tasks around various facilities, while Tesla continues to refine its abilities and add new features.
Tesla’s total investment could reach several billion dollars. Significant challenges lie ahead, including the creation of an entirely new manufacturing ecosystem, the refinement of AI systems for dependable autonomy, and the development of reliable supply chains for actuators, sensors, and other components.
Nevertheless, the visible progress at Giga Texas highlights Tesla’s capacity to translate ambitious concepts into physical reality.
Tesla’s Optimus factory stands as much more than a simple expansion project, as it is quite literally the second phase of what could potentially be the biggest product ever. With construction beginning, 2027 is poised to become a transformative year for Tesla, as it evolves even further from an electric vehicle leader into a pioneer of intelligent, general-purpose machines.
Tesla Vice President of Vehicle Engineering, Lars Moravy, recently revealed the company has thought about introducing a Plaid powertrain on the Model 3, but there could be some challenges involved.
On the Ride the Lightning podcast, Moravy revealed that he thinks about a Plaid Model 3 “all the time,” and it certainly has a place in Tesla’s potential lineup of future vehicles.
Now that the Plaid powertrain is technically defunct due to the newfound absence of the Model S and Model X, Tesla could find a way to reintroduce the lightning-quick trim level to its mass-market vehicles.
But there are going to be some challenges with it. Moravy said that the Model 3 Plaid would likely adopt the carbon-sleeved motors that the Model S Plaid had. However, packaging would be a major challenge, as Moravy said on the podcast, it would be a “tight engineering squeeze.”
It’s important to note that there are no active production plans for the Model 3 Plaid at this point, but it’s also worth noting that with the Model S and Model X Plaid no longer available, Tesla would likely be willing to introduce something that is even more white-knuckle than the Model 3 Performance, which already boasts a 2.9-second 0-60 MPH acceleration rate and a top speed of 163 MPH.
Of course, there is the Roadster, but we don’t know when that will exactly make it to market, and we know that, for sure, it will not be accessible to many.
Tesla unveils juicy new detail on the Roadster and hints at new unveil timeline
Tesla has prided itself in building some of the best cars out there, but they’re also interested in building cars that are simply fun to be in.
A Plaid Model 3 could truly push the limits and could end up being one of the best cars Tesla will ever build, especially if it can shave off at least half of a second from its 0-60 MPH time and increase its top speed slightly.
More than anything, the real changes will be in the ride and aerodynamics. Tesla improving things like the suspension, handling, and downforce will be the true trademarks of its Plaid powertrain; putting it in the Model 3 could be a great move for the company and for customers interested in high-end performance.
SpaceX to become America’s Military data backbone for missiles, drones, and warfighters
Tesla’s dedicated Optimus factory construction officially underway at Giga Texas
