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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 Optimus shows off its newest capability as progress accelerates

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Credit: Tesla

Tesla Optimus showed off its newest capability as progress on the project continues to accelerate toward an ultimate goal of mass production in the coming years.

Tesla is still developing Optimus and preparing for the first stages of mass production, where units would be sold and shipped to customers. CEO Elon Musk has always marketed the humanoid robot as the biggest product in history, even outside of Tesla, but of all time.

He believes it will eliminate the need to manually perform monotonous tasks, like cleaning, mowing the lawn, and folding laundry.

However, lately, Musk has revealed even bigger plans for Optimus, including the ability to relieve humans of work entirely within the next 20 years.

Development at Tesla’s Artificial Intelligence and Robotics teams has progressed, and a new video was shown of the robot taking a light jog with what appeared to be some pretty natural form:

Optimus has also made several public appearances lately, including one at the Neural Information Processing Systems, or NeurIPS Conference. Some spectators shared videos of Optimus’s charging rig, as well as its movements and capabilities, most interestingly, the hand:

The hand, forearm, and fingers have been one of the most evident challenges for Tesla in recent times, especially as it continues to work on its 3rd Generation iteration of Optimus.

Musk said during the Q3 Earnings Call:

“I don’t want to downplay the difficulty, but it’s an incredibly difficult thing, especially to create a hand that is as dexterous and capable as the human hand, which is incredible. The human hand is an incredible thing. The more you study the human hand, the more incredible you realize it is, and why you need four fingers and a thumb, why the fingers have certain degrees of freedom, why the various muscles are of different strengths, and fingers are of different lengths. It turns out that those are all there for a reason.”

The interesting part of the Optimus program so far is the fact that Tesla has made a lot of progress with other portions of the project, like movement, for example, which appears to have come a long way.

However, without a functional hand and fingers, Optimus could be rendered relatively useless, so it is evident that it has to figure this crucial part out first.

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Elon Musk and Tesla try to save legacy automakers from Déjà vu

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tesla interior operating on full self driving
Credit: TESLARATI

Elon Musk said in late November that he’s “tried to warn” legacy automakers and “even offered to license Tesla Full Self-Driving, but they don’t want it,” expressing frustration with companies that refuse to adopt the company’s suite, which will eventually be autonomous.

Tesla has long established itself as the leader in self-driving technology, especially in the United States. Although there are formidable competitors, Tesla’s FSD suite is the most robust and is not limited to certain areas or roadways. It operates anywhere and everywhere.

The company’s current position as the leader in self-driving tech is being ignored by legacy automakers, a parallel to what Tesla’s position was with EV development over a decade ago, which was also ignored by competitors.

The reluctance mirrors how legacy automakers initially dismissed EVs, only to scramble in catch-up mode years later–a pattern that highlights their historical underestimation of disruptive innovations from Tesla.

Elon Musk’s Self-Driving Licensing Attempts

Musk and Tesla have tried to push Full Self-Driving to other car companies, with no true suitors, despite ongoing conversations for years. Tesla’s FSD is aiming to become more robust through comprehensive data collection and a larger fleet, something the company has tried to establish through a subscription program, free trials, and other strategies.

Tesla CEO Elon Musk sends rivals dire warning about Full Self-Driving

However, competing companies have not wanted to license FSD for a handful of speculative reasons: competitive pride, regulatory concerns, high costs, or preference for in-house development.

Déjà vu All Over Again

Tesla tried to portray the importance of EVs long ago, as in the 2010s, executives from companies like Ford and GM downplayed the importance of sustainable powertrains as niche or unprofitable.

Musk once said in a 2014 interview that rivals woke up to electric powertrains when the Model S started to disrupt things and gained some market share. Things got really serious upon the launch of the Model 3 in 2017, as a mass-market vehicle was what Tesla was missing from its lineup.

This caused legacy companies to truly wake up; they were losing market share to Tesla’s new and exciting tech that offered less maintenance, a fresh take on passenger auto, and other advantages. They were late to the party, and although they have all launched vehicles of their own, they still lag in two major areas: sales and infrastructure, leaning on Tesla for the latter.

Musk’s past warnings have been plentiful. In 2017, he responded to critics who stated Tesla was chasing subsidies. He responded, “Few people know that we started Tesla when GM forcibly recalled all electric cars from customers in 2003 and then crushed them in a junkyard,” adding that “they would be doing nothing” on EVs without Tesla’s efforts.

Companies laughed off Tesla’s prowess with EVs, only to realize they had made a grave mistake later on.

It looks to be happening once again.

A Pattern of Underestimation

Both EVs and self-driving tech represent major paradigm shifts that legacy players view as threats to their established business models; it’s hard to change. However, these early push-aways from new tech only result in reactive strategies later on, usually resulting in what pains they are facing now.

Ford is scaling back its EV efforts, and GM’s projects are hurting. Although they both have in-house self-driving projects, they are falling well behind the progress of Tesla and even other competitors.

It is getting to a point where short-term risk will become a long-term setback, and they may have to rely on a company to pull them out of a tough situation later on, just as it did with Tesla and EV charging infrastructure.

Tesla has continued to innovate, while legacy automakers have lagged behind, and it has cost them dearly.

Implications and Future Outlook

Moving forward, Tesla’s progress will continue to accelerate, while a dismissive attitude by other companies will continue to penalize them, especially as time goes on. Falling further behind in self-driving could eventually lead to market share erosion, as autonomy could be a crucial part of vehicle marketing within the next few years.

Eventually, companies could be forced into joint partnerships as economic pressures mount. Some companies did this with EVs, but it has not resulted in very much.

Self-driving efforts are not only a strength for companies themselves, but they also contribute to other things, like affordability and safety.

Tesla has exhibited data that specifically shows its self-driving tech is safer than human drivers, most recently by a considerable margin. This would help with eliminating accidents and making roads safer.

Tesla’s new Safety Report shows Autopilot is nine times safer than humans

Additionally, competition in the market is a good thing, as it drives costs down and helps innovation continue on an upward trend.

Conclusion

The parallels are unmistakable: a decade ago, legacy automakers laughed off electric vehicles as toys for tree-huggers, crushed their own EV programs, and bet everything on the internal-combustion status quo–only to watch Tesla redefine the industry while they scrambled for billions in catch-up capital.

Today, the same companies are turning down repeated offers to license Tesla’s Full Self-Driving technology, insisting they can build better autonomy in-house, even as their own programs stumble through recalls, layoffs, and missed milestones. History is not merely rhyming; it is repeating almost note-for-note.

Elon Musk has spent twenty years warning that the auto industry’s bureaucratic inertia and short-term thinking will leave it stranded on the wrong side of technological revolutions. The question is no longer whether Tesla is ahead–it is whether the giants of Detroit, Stuttgart, and Toyota will finally listen before the next wave leaves them watching another leader pull away in the rear-view mirror.

This time, the stakes are not just market share; they are the very definition of what a car will be in the decades ahead.

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Waymo driverless taxi drives directly into active LAPD standoff

No injuries occurred, and the passengers inside the vehicle were safely transported to their destination, as per a Waymo representative.

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Credit: Alex Choi/Instagram

A video posted on social media has shown an occupied Waymo driverless taxi driving directly into the middle of an active LAPD standoff in downtown Los Angeles. 

As could be seen in the short video, which was initially posted on Instagram by user Alex Choi, a Waymo driverless taxi drove directly into the middle of an active LAPD standoff in downtown Los Angeles. 

The driverless taxi made an unprotected left turn despite what appeared to be a red light, briefly entering a police perimeter. At the time, officers seemed to be giving commands to a prone suspect on the ground, who looked quite surprised at the sudden presence of the driverless vehicle. 

People on the sidewalk, including the person who was filming the video, could be heard chuckling at the Waymo’s strange behavior. 

The Waymo reportedly cleared the area within seconds. No injuries occurred, and the passengers inside the vehicle were safely transported to their destination, as per a Waymo representative. Still, the video spread across social media, with numerous netizens poking fun at the gaffe. 

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Others also pointed out that such a gaffe would have resulted in widespread controversy had the vehicle involved been a Tesla on FSD. Tesla is constantly under scrutiny, with TSLA shorts and similar groups actively trying to put down the company’s FSD program.

A Tesla on FSD or Robotaxi accidentally driving into an active police standoff would likely cause lawsuits, nonstop media coverage, and calls for a worldwide ban, at the least.

This was one of the reasons why even minor traffic infractions committed by the company’s Robotaxis during their initial rollout in Austin received nationwide media attention. This particular Waymo incident, however, will likely not receive as much coverage.  

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