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
Elon Musk’s Boring Co goes extra hard in Nashville with first rock-crushing TBM
The Boring Company’s machine for the project is now in final testing.
The Boring Company is gearing up to tackle one of its toughest projects yet, a new tunnel system beneath Nashville’s notoriously tough limestone terrain. Unlike the soft-soil conditions of Las Vegas and Austin, the Music City Loop will require a “hard-rock” boring machine capable of drilling through dense, erosion-resistant bedrock.
The Boring Company’s machine for the project is now in final testing.
A boring hard-rock tunneling machine
The Boring Company revealed on X that its new hard-rock TBM can generate up to 4 million pounds of grip force and 1.5 million pounds of maximum thrust load. It also features a 15-filter dust removal system designed to keep operations clean and efficient during excavation even in places where hard rock is present.
Previous Boring Co. projects, including its Loop tunnels in Las Vegas, Austin, and Bastrop, were dug primarily through soft soils. Nashville’s geology, however, poses a different challenge. Boring Company CEO and President Steve Davis mentioned this challenge during the project’s announcement in late July.
“It’s a tough place to tunnel, Nashville. If we were optimizing for the easiest places to tunnel, it would not be here. You have extremely hard rock, like way harder than it should be. It’s an engineering problem that’s fairly easy and straightforward to solve,” Davis said.
Nashville’s limestone terrain
Experts have stated that the city’s subsurface conditions make it one of the more complex tunneling environments in the U.S. The Outer Nashville Basin is composed of cherty Mississippian-age limestone, a strong yet soluble rock that can dissolve over time, creating underground voids and caves, as noted in a report from The Tennessean.
Jakob Walter, the founder and principal engineer of Haushepherd, shared his thoughts on these challenges. “Limestone is generally a stable sedimentary bedrock material with strength parameters that are favorable for tunneling. Limestone is however fairly soluble when compared to other rack materials, and can dissolve over long periods of time when exposed to water.
“Unexpected encounters with these features while tunneling can result in significant construction delays and potential instability of the excavation. In urban locations, structures at the ground surface should also be constantly monitored with robotic total stations or similar surveying equipment to identify any early signs of movement or distress,” he said.
Elon Musk
Elon Musk shares ridiculous fact about Optimus’ hand demos
It appears that Optimus’ V3 iteration is still very much under wraps.
Elon Musk recently revealed something quite shocking about the Optimus demonstration hand that was showcased at the 2025 Annual Shareholder Meeting. As per the CEO, the complex robotic hand that impressed the event’s attendees was not a component of Optimus V3 at all.
Needless to say, it appears that Optimus’ V3 iteration is still very much under wraps.
Optimus’s hand
Even in Tesla’s We, Robot event last year, the company showcased a robotic hand that seemed capable of performing complex tasks. A similar hand was showcased at the recent investor event. It was then no surprise that some attendees and EV community members assumed that the robotic component, which was very dexterous, was a preview of Optimus V3’s hand.
As per Elon Musk in a recent post on X, however, this was not the case. While the robotic hand that Tesla showcased at the 2025 Annual Shareholder Meeting was already very impressive, it was still a V2 component. In response to a quote post from his mom Maye Musk, who noted that “Elon told me a few times that the hand is the most difficult part of the robot,” Elon Musk clarified that the impressive component was still from Optimus V2.
“This is just the V2 Optimus hand. The V3 hand is another level beyond this. Exquisite engineering,” Musk wrote in his post on X.
Not like Tesla
Tesla is designing Optimus to be a potential replacement for humans in some of the world’s most delicate tasks, such as surgery. It is then extremely important for Optimus’ hand to be very dexterous and refined in its movements. This is something that even companies that are also producing humanoid robots have yet to accomplish fully. Musk highlighted this during the Annual Shareholder Meeting, when he discussed how Tesla is really the only company that can scale humanoid robots properly.
“You will see certainly many companies showing demonstration robots. There’s really three things that are super difficult about robots. One is the engineering of the forearm and hand because the human hand is an incredible thing, actually. It’s super dexterous.
“So, engineering the hand really well, the real-world AI, and then volume manufacturing. Those are generally the things that are missing. One or more of those things are missing from other companies. So Tesla is the only one that has all three of those,” Musk said.
Energy
Tesla starts hiring efforts for Texas Megafactory
Tesla’s Brookshire site is expected to produce 10,000 Megapacks annually, equal to 40 gigawatt hours of energy storage.
Tesla has officially begun hiring for its new $200 million Megafactory in Brookshire, Texas, a manufacturing hub expected to employ 1,500 people by 2028. The facility, which will build Tesla’s grid-scale Megapack batteries, is part of the company’s growing energy storage footprint.
Tesla’s hiring efforts for the Texas Megafactory are hinted at by the job openings currently active on the company’s Careers website.
Tesla’s Texas Megafactory
Tesla’s Brookshire site is expected to produce 10,000 Megapacks annually, equal to 40 gigawatt hours of energy storage, similar to the Lathrop Megafactory in California. Tesla’s Careers website currently lists over 30 job openings for the site, from engineers, welders, and project managers. Each of the openings is listed for Brookshire, Texas.
The company has leased two buildings in Empire West Business Park, with over $194 million in combined property and equipment investment. Tesla’s agreement with Waller County includes a 60% property tax abatement, contingent on meeting employment benchmarks: 375 jobs by 2026, 750 by 2027, and 1,500 by 2028, as noted in a report from the Houston Business Journal. Tesla is required to employ at least 1,500 workers in the facility through the rest of the 10-year abatement period.
Tesla’s clean energy boom
City officials have stated that Tesla’s arrival marks a turning point for the Texas city, as it highlights a shift from logistics to advanced clean energy manufacturing. Ramiro Bautista from Brookshire’s economic development office, highlighted this in a comment to the Journal.
“(Tesla) has great-paying jobs. Not just that, but the advanced manufacturing (and) clean energy is coming to the area,” he said. “So it’s not just your normal logistics manufacturing. This is advanced manufacturing coming to this area, and this brings a different type of job and investment into the local economy.”
Elon Musk’s Boring Co goes extra hard in Nashville with first rock-crushing TBM
Elon Musk shares ridiculous fact about Optimus’ hand demos
Tesla starts hiring efforts for Texas Megafactory
-
News5 days agoTesla shares rare peek at Semi factory’s interior
-
Elon Musk5 days agoTesla says texting and driving capability is coming ‘in a month or two’
-
News4 days agoTesla makes online ordering even easier
-
News4 days agoTesla Model Y Performance set for new market entrance in Q1
-
News5 days agoTesla Cybercab production starts Q2 2026, Elon Musk confirms
-
News5 days agoTesla China expecting full FSD approval in Q1 2026: Elon Musk
-
News6 days agoTesla Model Y Performance is rapidly moving toward customer deliveries
-
News3 days agoTesla is launching a crazy new Rental program with cheap daily rates