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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 Model Y on FSD saves couple after encountering King of edge cases

Experts have noted that if confirmed, this could be the world’s first recorded meteorite collision involving a Tesla.

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Credit: @10NewsAU/YouTube

A South Australian Tesla driver is thanking his Model Y’s Full Self-Driving system after a mysterious object, possibly a meteorite, slammed into his car’s windshield while it had FSD engaged. 

The impact sent hot glass fragments flying through the cabin as the vehicle continued driving without human input through the darkness. Experts have noted that if confirmed, this could be the world’s first recorded meteorite collision involving a Tesla.

The Tesla owner was enjoying a quiet drive home when they hit the king of edge cases

Veterinarian Dr. Andrew Melville-Smith and his wife were traveling north on Augusta Highway on the night of October 19 when a sudden blast struck their newly delivered Model Y. At the time, it was clear, pitch black night, and Dr. Melville-Smith and his wife were just listening to a podcast while FSD was operating the vehicle, as noted in a Yahoo News report. 

Suddenly, something hit the Tesla’s windshield. “Then there was, (what) I can only describe as a very, very violent explosion. The whole inside of the car was literally blasted with glass fragments. It was full of white smoke, and it smelled like the car was on fire,” Dr. Melville-Smith stated. 

The vet stated that he and his wife were stunned for a good 10 seconds, and for a bit, he and his wife thought they had crashed. Images of the crash’s aftermath showed a massive crack on the Tesla’s windshield, which Dr. Melville-Smith noted was hot to the touch. The object that hit the Tesla’s windshield was so hot that part of the vehicle’s windshield was partly melted. 

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FSD kept driving despite the possible meteorite strike

Thankfully, the Tesla was operating with its FSD (Supervised) system engaged at the time. Thus, despite the vehicle being hit by what might be a literal meteorite, and despite Dr. Melville-Smith and his wife being stunned because of the impact, their Tesla just kept driving steadily. 

“I thought we’d had an accident, but then I looked at the screen and went ‘Oh, we’re still driving. We were moving around, so it obviously thought we were paying attention, and it was happy to keep driving to Port Augusta. After we pulled over, we saw the big crater in the windscreen,” the vet said. 

The South Australian Museum is now examining the case, with geologist Dr. Kieran Meaney stating the scorched glass and heat damage do suggest a potential meteorite strike. “The little detail that’s really selling it for me at the moment is that whatever it was that hit the windscreen seems to have been very hot,” Meaney explained. However, the object has yet to be recovered.

Check out a video of the remarkable edge case below.

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“Foundation:” Elon Musk wants to send a record of Grokipedia to space

The idea sounds outlandish, though it is also something that is in character for the CEO.

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Credit: xAI

Elon Musk has announced one of his latest initiatives, and it is every bit as sci-fi as it is surprisingly grounded. In a post on X, Musk stated that Grokipedia, xAI’s new open-source encyclopedia, will be etched into stable oxide and launched into space. 

The idea sounds outlandish, though it is also something that is in character for the CEO.

Preserving human knowledge among the stars

Musk posted his plan following the launch of Grokipedia’s V0.1’s iteration. The CEO congratulated the xAI team for the online encyclopedia’s launch, though he also stated that the goal for Grokipedia is to create an open-source collection of knowledge. This would then be distributed to the cosmos.

“Nice work by the xAI team on Grokipedia! The goal here is to create an open source, comprehensive collection of all knowledge. Then place copies of that etched in a stable oxide in orbit, the Moon, and Mars to preserve it for the future. Foundation,” Musk wrote in his post.

While seemingly outlandish, this is not the first time that a record of human knowledge of sorts was sent out to space. In 1977, the Voyager Golden Record was launched aboard NASA’s Voyager 1 and 2 spacecraft. The record contains sounds and images that ere aggregated to portray the diversity of the Earth’s culture. Of course, Musk’s plan with Grokipedia, is infinitely more ambitious. 

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Grokipedia and AI neutrality

Musk launched Grokipedia as an AI-driven alternative to Wikipedia, designed to eliminate the human biases that could affect conventional online knowledge platforms. The system is powered by xAI’s Grok, which scrape and summarize information from across the internet, offering balanced and nuanced coverage of topics ranging from science and technology to culture and politics.

Unlike Wikipedia’s human-edited format, Grokipedia would be able to evolve through machine learning, reading vastly more material than any editorial team could. Early testers, including Wikipedia co-founder Larry Sanger, praised its initial version as “very OK” and potentially more neutral than Wikipedia. Musk agreed, stating that even in its V0.1 form, Grokipedia is “already better than Wikipedia.”

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Tesla Cybertrucks to save Las Vegas police thousands in fuel and maintenance

Sheriff Kevin McMahill unveiled the new vehicles on Monday, describing them as “the next evolution to keep our community safer than it’s ever been.”

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Credit: @Sheriff_LVMPD/X

The Las Vegas Metropolitan Police Department has officially unveiled its fleet of Tesla Cybertrucks as part of its push toward a more advanced, cost-efficient, and sustainable patrol system. 

Sheriff Kevin McMahill unveiled the new vehicles on Monday, describing them as “the next evolution to keep our community safer than it’s ever been.” The trucks are expected to begin service across all area commands within two weeks.

High-tech patrol fleet

Each UP.FIT-modified Cybertruck has been customized with ladders, shields, and less-lethal equipment to support law enforcement operations. The vehicles will connect to a live drone response hub capable of facial recognition and gunshot detection, enabling drones to launch automatically when alerts trigger. The system streams real-time footage directly to responding officers, enhancing both speed and situational awareness during emergencies.

Officers have already completed training with the new fleet and offered feedback on its performance, according to Fox 5 Vegas. Sheriff McMahill noted that the trucks, along with robot dogs and SWAT vehicles, represent a coordinated effort to combine human expertise with emerging technologies. The Cybertruck rollout was made possible through a donation from the Horowitz family.

Cybertrucks’ major savings

The department’s ten UP.FIT patrol Cybertrucks are among the most American-made law enforcement vehicles available, featuring roughly twice the domestic parts content of comparable Ford and Chevrolet patrol trucks. Beyond their build quality, the electric fleet offers major cost benefits. Each Cybertruck is projected to save between $8,800 and $12,000 in annual fuel costs and roughly $3,540 in maintenance over a five-year service life.

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With regenerative braking, factory ballistic-resistant doors, and no idling fuel burn, the Cybertruck platform provides higher uptime, lower total cost of ownership, and a quieter patrol experience, all while reducing the department’s carbon footprint. Sheriff McMahill confirmed each area command will receive one of the new patrol units.

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