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SpaceX’s orbit-ready Crew Dragon nears first trip out to Pad 39A atop Falcon 9

The DM-1 Crew Dragon shows off its elegant conformal solar array, featuring curved solar cells with no mechanical deployment mechanism. (SpaceX)

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Now primarily reserved for launches involving the company’s Falcon Heavy rocket and Crew Dragon spacecraft, SpaceX has begun touching up its Launch Complex 39A (LC-39A) pad with new paint and hardware in anticipation of the first orbital launch of Crew Dragon, set to occur as early as the evening of January 17th.

A little over three weeks away from the milestone mission’s launch, SpaceX has – even more importantly – rolled Pad 39A’s transporter/erector (T/E) into an on-site hangar, where Falcon 9 B1051 and Crew Dragon C201 are awaiting final integration and fit checks prior to a series of careful dress rehearsals including a dry (mission) rehearsal, a wet rehearsal (WDR), and an on-pad static fire.

Over the past month or two, SpaceX’s Florida pad technicians have gradually begun a number of small but important modifications to Launch Complex 39A (LC-39A, Pad 39A), primarily focused on what is known as its Fixed Service Structure (FSS), a tall and rectangular tower off to the side of SpaceX’s launch mount. Notably, SpaceX has completed the demolition and removal of all extraneous Pad 39A structures related to its decades of service under the Space Shuttle program and has further modified the FSS to allow for the installation of Crew Dragon’s Crew Access Arm (CAA), completed earlier in 2018.

With those major tasks complete, SpaceX workers have since subtly modified the pad’s transporter/erector (T/E) for Crew Dragon and begun to both paint and clad the tower, both designed to minimize wear and tear from regular launch operations and coastal Florida’s omnipresent sea breeze. Captured in photos from the November 2018 launch of Es’hail-2, the tower cladding appears to be made of double-layered sheets of half-opaque black plastic, while the paint of choice is gray (and black accents) to mesh with the tower’s minimalist arm.

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Given CEO Elon Musk’s well-known preference that his companies, products, and facilities look “beautiful”, this is almost certainly being done on his whim, albeit for the best. A coat of paint and minimalist arm design are probably cost a minimal amount of money and effort, but the bare minimum still easily sets SpaceX’s facilities apart from competitors like ULA and even NASA.

 

Crew Dragon closes in on orbital launches

For perhaps the first in the history of NASA’s Commercial Crew Program (CCP), SpaceX revealed earlier this month that all the major hardware components needed for the first orbital launch of Crew Dragon were under one literal roof at the company’s Pad 39A launch complex. In the weeks and months prior, both Musk and COO/President Gwynne Shotwell stated rather explicitly that that hardware would indeed be physically ready to launch no later than the end of 2018, even suggesting that SpaceX engineers and technicians would attempt to conduct a dry (propellant-less) Mission Dress Rehearsal (MDR) to ensure everything fits together in late December.

As of last week, 39A’s T/E disappeared from its launch mount, indicating that the pad crew had rolled the massive apparatus into the complex’s integration hangar, where the above Falcon 9(s) and Demo-1 Crew Dragon were stashed as of December 18th. Having spent a solid five days in the hangar, SpaceX technicians have likely begun or even completed the integration of Falcon 9 B1051 and Crew Dragon and proceeded to integrate that full rocket/spacecraft combo to the T/E. As such, the T/E could very well roll out of its hangar with Falcon 9 and Crew Dragon attached at almost any moment between now and 2019.

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If all goes as planned and NASA and SpaceX can wrap up paperwork (certification, approvals, etc) in the next week or two, SpaceX could launch an uncrewed Crew Dragon into orbit as early as the evening of January 17th. The rocket’s rollout will be the be the next major milestone so stay tuned!


For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet check out our brand new LaunchPad and LandingZone newsletters!

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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Investor's Corner

Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

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Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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Investor's Corner

Tesla uber bull Ron Baron says ‘the time to buy the stock is now’

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Credit: Tesla

In a new interview on Wednesday, Tesla uber bull Ron Baron said that anyone looking to buy the company’s stock should do so as soon as they can.

Baron, founder and CEO of Baron Capital and one of Tesla’s most persistent institutional bulls, used a CNBC Squawk Box appearance on Wednesday to deliver a familiar message with fresh urgency: In his opinion, Tesla stock is a buy:

“The time to buy the stock is now. FSD is catching on, and it’s going to be bigger and bigger. 55% of new buyers are buying it (Teslas) with FSD. It’s going to be everywhere. It’s safer.”

The Baron Capital frontman’s case is built around Full Self-Driving. Tesla reported 1.48 million active FSD subscriptions in the second quarter, up 56 percent year over year, and company officials have said roughly 55 percent of new North American deliveries left with a subscription enabled.

Baron framed that attach rate as proof the product is moving from enthusiast extra to default expectation, and as a reason software, not just vehicle volume, should drive the next phase of value.

His conviction on Tesla shares is not theoretical, as Baron Capital made its first Tesla investment in 2014, after years of meetings that began around the 2010 IPO roadshow. The firm later built a large SpaceX position starting in 2017.

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Baron said those Musk-led bets have generated about $30 billion of the $71 billion in profits Baron Capital has produced for clients. He put the firm’s current exposure at roughly $25 billion in SpaceX and $5 billion in Tesla. Personally, he described SpaceX as his largest holding, at about $5 billion, with about $1.5 billion in Tesla and additional Tesla exposure through the firm’s funds.

That concentration is also a statement of loyalty. Asked about talk of a SpaceX-Tesla combination, Baron said he had already walked Elon Musk through arguments for and against a deal, then declined to repeat them on air. His public position was simpler: “Whatever you decide is better is what I’m going to support,” he said to Musk.

Baron also said that he picked up the farewell edition of the Model S after Tesla decided to sunset the vehicle earlier this year, calling it his favorite car he’s ever driven.

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