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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.
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Tesla Semis to get 18 new Megachargers at this PepsiCo plant
PepsiCo is set to add more Tesla Semi Megachargers, this time at a facility in North Carolina.
Tesla partner PepsiCo is set to build new Semi charging stations at one of its manufacturing sites, as revealed in new permitting plans shared this week.
On Friday, Tesla charging station scout MarcoRP shared plans on X for 18 Semi Megacharging stalls at PepsiCo’s facility in Charlotte, North Carolina, coming as the latest update plans for the company’s increasingly electrified fleet. The stalls are set to be built side by side, along with three Tesla Megapack grid-scale battery systems.
The plans also note the faster charging speeds for the chargers, which can charge the Class 8 Semi at speeds of up to 1MW. Tesla says that the speed can charge the Semi back to roughly 70 percent in around 30 minutes.
You can see the site plans for the PepsiCo North Carolina Megacharger below.
Credit: PepsiCo (via MarcoRPi1 on X)
Credit: PepsiCo (via MarcoRPi1 on X)
READ MORE ON THE TESLA SEMI: Tesla to build Semi Megacharger station in Southern California
PepsiCo’s Tesla Semi fleet, other Megachargers, and initial tests and deliveries
PepsiCo was the first external customer to take delivery of Tesla’s Semis back in 2023, starting with just an initial order of 15. Since then, the company has continued to expand the fleet, recently taking delivery of an additional 50 units in California. The PepsiCo fleet was up to around 86 units as of last year, according to statements from Semi Senior Manager Dan Priestley.
Additionally, the company has similar Megachargers at its facilities in Modesto, Sacramento, and Fresno, California, and Tesla also submitted plans for approval to build 12 new Megacharging stalls in Los Angeles County.
Over the past couple of years, Tesla has also been delivering the electric Class 8 units to a number of other companies for pilot programs, and Priestley shared some results from PepsiCo’s initial Semi tests last year. Notably, the executive spoke with a handful of PepsiCo workers who said they really liked the Semi and wouldn’t plan on going back to diesel trucks.
The company is also nearing completion of a higher-volume Semi plant at its Gigafactory in Nevada, which is expected to eventually have an annual production capacity of 50,000 Semi units.
Tesla executive teases plan to further electrify supply chain
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Tesla sales soar in Norway with new Model Y leading the charge
Tesla recorded a 54% year-over-year jump in new vehicle registrations in June.
Tesla is seeing strong momentum in Norway, with sales of the new Model Y helping the company maintain dominance in one of the world’s most electric vehicle-friendly markets.
Model Y upgrades and consumer preferences
According to the Norwegian Road Federation (OFV), Tesla recorded a 54% year-over-year jump in new vehicle registrations in June. The Model Y led the charge, posting a 115% increase compared to the same period last year. Tesla Norway’s growth was even more notable in May, with sales surging a whopping 213%, as noted in a CNBC report.
Christina Bu, secretary general of the Norwegian EV Association (NEVA), stated that Tesla’s strong market performance was partly due to the updated Model Y, which is really just a good car, period.
“I think it just has to do with the fact that they deliver a car which has quite a lot of value for money and is what Norwegians need. What Norwegians need, a large luggage space, all wheel drive, and a tow hitch, high ground clearance as well. In addition, quite good digital solutions which people have gotten used to, and also a charging network,” she said.
Tesla in Europe
Tesla’s success in Norway is supported by long-standing government incentives for EV adoption, including exemptions from VAT, road toll discounts, and access to bus lanes. Public and home charging infrastructure is also widely available, making the EV ownership experience in the country very convenient.
Tesla’s performance in Europe is still a mixed bag, with markets like Germany and France still seeing declines in recent months. In areas such as Norway, Spain, and Portugal, however, Tesla’s new car registrations are rising. Spain’s sales rose 61% and Portugal’s sales rose 7% last month. This suggests that regional demand may be stabilizing or rebounding in pockets of Europe.
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Tesla to open first India experience center in Mumbai on July 15
The event is scheduled for July 15 at the Bandra Kurla Complex, a premier business district in Mumbai.
Tesla is officially entering India with the opening of its first showroom and experience center in Mumbai next week. The event is scheduled for July 15 at the Bandra Kurla Complex, a premier business district in Mumbai.
Tesla imports to India signal an early-stage market entry strategy
According to Indian customs data, Tesla has imported approximately $1 million worth of vehicles, charging equipment, and merchandise into the country between January and June. The shipments include six Model Y comprised of five standard variants valued at $32,500 each and one long-range model valued at $46,000. Several Superchargers and related accessories were also imported into the country, as noted in a Yahoo Finance report.
These vehicles are expected to serve as display models and test units as Tesla gauges interest and navigates India’s high import duties, which hover around 70% on fully built vehicles. Despite the significant tariffs in the country, Tesla has opted to begin its India expansion with imported cars.
An invitation to the Tesla India launch event has been making the rounds online. As could be seen in the document, Tesla noted that July 15 would be the launch of Tesla in India through the opening of a Tesla experience centre at Bandra Kurla Complex in Mumbai.
Tesla India’s hiring and expansion efforts are underway
Tesla has filled a number of key roles from the 30+ positions it advertised earlier this year. Recent hires include store managers, service executives, and sales staff, while ongoing recruitment is focused on supply chain engineers and vehicle operators to support the company’s Autopilot program.
Indian officials have been open about their intention to encourage Tesla to establish a manufacturing hub in the country. Tesla does seem open to the idea, at least, with reports last year hinting that Elon Musk was set to visit the country to discuss or even potentially announce a domestic project. The trip, however, was ultimately canceled.
Tesla Semis to get 18 new Megachargers at this PepsiCo plant
Tesla sales soar in Norway with new Model Y leading the charge
Tesla to open first India experience center in Mumbai on July 15
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