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SpaceX rapidly tests, ships Falcon 9 second stage for next NASA astronaut launch

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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.

A new Falcon upper stage bearing NASA insignias was first spotted in Texas on October 2nd.
Less than two weeks later, that same upper stage may have arrived in Cape Canaveral, Florida.

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.

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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.

The first orbit-ready Crew Dragon spacecraft stands beside its human-rated Falcon 9 rocket (upper stage included) in December 2018. (SpaceX)

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.

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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 celebrates 75k Superchargers, less than 5 months since 70k-stall milestone

Tesla’s 75,000th stall is hosted at the South Hobart Smart Store on Cascade Road, South Hobart, Tasmania.

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Credit: Tesla Charging/X

Tesla has crossed another major charging milestone by officially installing its 75,000th Supercharger stall worldwide. The electric vehicle maker chose South Hobart, Tasmania, as the commemorative location of its 75,000th Supercharger. 

Tesla’s 75,000th Supercharger

Tesla’s 75,000th stall is hosted at the South Hobart Smart Store on Cascade Road, South Hobart, TAS 7004, as noted in a techAU report. The location features four next-generation V4 Superchargers, which are built with longer cables that should make it easy even for non-Teslas to use the rapid charger. The site also includes simplified payment options, aligning with Tesla’s push to make V4 stations more accessible to a broader set of drivers.

For Tasmanian EV owners, the installation fills an important regional gap, improving long-distance coverage around Hobart and strengthening the area’s appeal for mainland travelers traveling by electric vehicle. Similar to other commemorative Superchargers, the 70,000th stall is quite special as it is finished in Glacier Blue paint. Tesla’s 50,000th stall, which is in California, is painted a stunning red, and the 60,000th stall, which is in Japan, features unique origami-inspired graphics.

https://twitter.com/TeslaCharging/status/1991019320584122471?s=20

Accelerating Supercharger milestones

The Tesla Supercharger’s pace of expansion shows no signs of slowing. Tesla celebrated its 70,000th stall at a 12-stall site in Burleson, Texas late June 2025. Just eight months earlier, Tesla announced that it had celebrated the buildout of its 60,000th Supercharger, which was built in Enshu Morimachi, Shizuoka Prefecture, Japan.

Tesla’s Supercharger Network also recently received accolades in the United Kingdom, with the 2025 Zapmap survey naming the rapid charging system as the Best Large EV Charging Network for the second year in a row. Survey respondents praised the Supercharger Network for its ease of use, price, and reliability, which is best-in-class. The fact that the network has also been opened for non-Teslas is just icing on the cake. 

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Luminar-Volvo breakdown deepens as lidar maker warns of potential bankruptcy

The automaker stated that Luminar failed to meet contractual obligations.

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Volvo-bev-production-europe-vs-china
(Credit: Volvo)

Luminar’s largest customer, Volvo, has canceled a key five-year contract as the lidar supplier warned investors that it might be forced to file for bankruptcy. The automaker stated that Luminar failed to meet contractual obligations, escalating a dispute already unfolding as Luminar defaults on loans, undergoes layoffs, and works to sell portions of the business.

Volvo pulls back on Luminar

In a statement to TechCrunch, Volvo stated that Luminar’s failure to deliver its contractual obligations was a key driver of the cancellation of the contract. “Volvo Cars has made this decision to limit the company’s supply chain risk exposure and it is a direct result of Luminar’s failure to meet its contractual obligations to Volvo Cars,” Volvo noted in a statement.

The rift marked a notable turn for the two companies, whose relationship dates back several years. Volvo invested in Luminar early and helped push its sensors into production programs, while Luminar’s technology bolstered the credibility of Volvo’s safety-focused autonomous driving plans. Volvo’s partnership also supported Luminar’s 2020 SPAC listing, which briefly made founder Austin Russell one of the youngest self-made billionaires in the industry.

Damaged Volvo relations

The damaged Volvo partnership comes during a critical period for Luminar. The company has defaulted on several loans and warned investors that bankruptcy remains a possibility if restructuring discussions fall through. To conserve cash, Luminar has cut 25% of its workforce and is exploring strategic alternatives, including partial or full asset sales. 

One potential buyer is founder Austin Russell, who resigned as CEO in May amid a board-initiated ethics inquiry. The company is also the subject of an ongoing SEC investigation.

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Luminar, for its part, also noted in a filing that it had “made a claim against Volvo for significant damages” and “suspended further commitments of Iris” for the carmaker. “The Company is in discussions with Volvo concerning the dispute; however, there can be no assurance that the dispute will be resolved favorably or at all,” the lidar maker stated.

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Elon Musk says he’s open to powering Apple’s Siri with xAI’s Grok

Siri, one of the first intelligent AI assistants in the market, has become widely outdated and outperformed by rivals over the years.

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Gage Skidmore, CC BY-SA 4.0 , via Wikimedia Commons

Elon Musk says he’s willing to help Apple overhaul Siri by integrating xAI’s Grok 4.1, igniting widespread excitement and speculations about a potential collaboration between the two tech giants. 

Siri, one of the first intelligent AI assistants in the market, has become widely outdated and outperformed by rivals over the years.

Musk open to an Apple collaboration

Musk’s willingness to team up with Apple surfaced after an X user suggested replacing Siri with Grok 4.1 to modernize the AI assistant. The original post criticized Siri’s limitations and urged Apple to adopt a more advanced AI system. “It’s time for Apple to team up with xAI and actually fix Siri. Replace that outdated, painfully dumb assistant with Grok 4.1. Siri deserves to be Superintelligent,” the X user wrote.

Musk quoted the post, responding with, “I’m down.” Musk’s comment quickly attracted a lot of attention among X’s users, many of whom noted that a Grok update to Siri would be appreciated because Apple’s AI assistant has legitimately become terrible in recent years. Others also noted that Grok, together with Apple’s potential integration of Starlink connectivity, would make iPhones even more compelling. 

https://twitter.com/elonmusk/status/1990651578965967050?s=20

Grok promises major Siri upgrades

The enthusiasm stems largely from Grok 4.1’s technical strengths, which include stronger reasoning and improved creative output. xAI also designed the model to reduce hallucinations, as noted in a Reality Tea report. Supporters believe these improvements could address Apple’s reported challenges developing its own advanced AI systems, giving Siri the upgrade many users have waited years for.

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Reactions ranged from humorous to hopeful, with some users joking that Siri would finally “wake up with a personality” if paired with Grok. Siri, after all, was a trailblazer in voice assistants, but it is currently dominated by rivals in terms of features and capabilities. Grok could change that, provided that Apple is willing to collaborate with Elon Musk’s xAI.

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