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SpaceX, Polaris reveal plans to launch private astronauts higher than ever before
SpaceX and Inspiration4 creator Jared Isaacman have announced the Polaris Program, an initiative designed to carry the torch forward from Inspiration4 with even more ambitious private astronaut launches.
In September 2021, four astronauts became the first all-private crew to launch into orbit on a mission known as Inspiration4. First and foremost, I4’s goal was to uplift St. Jude’s Children’s Hospital and raise money for the fight against childhood cancer. It undeniably succeeded in that regard, raising almost a quarter of a billion dollars – about half of which came from public donations. The mission also catapulted SpaceX into the spotlight and appeared to mark the very beginning of the company’s private human spaceflight ambitions.
Combined with a separate program from Axiom Space, which has already booked four fully private astronaut missions to the International Space Station (ISS), the creation of the Polaris Program appears to confirm as much.
SpaceX now has six private Crew Dragon launches scheduled within the next few years. Polaris adds at least two missions, beginning as early as Q4 2022. Known as Polaris Dawn, the mission will be Crew Dragon’s second free-flyer mission after Inspiration4, meaning that the spacecraft will fly on its own for the full five-day duration. That gives SpaceX and the Polaris team far more freedom, freedom that they plan to take advantage of.
SpaceX aspires for Polaris Dawn to be the highest Earth orbit humans have traveled to since the 1960s and the furthest humans have been from the planet since the 1970s. NASA’s Apollo missions, which sent humans to the Moon, hold the all-time record, which Polaris Dawn will barely scratch the surface of. But in Earth orbit, the record – 1368 kilometers (850 mi) – was set by Gemini XI in September 1966.
With a drone ship landing for the booster, Falcon 9 is officially capable of launching around 12 metric tons (26,000 lb) to a circular 1400 km (870 mi) orbit. For unknown reasons, SpaceX and NASA have never acknowledged Crew Dragon’s mass at liftoff, but the first uncrewed vehicle weighed around 12 tons when it docked with the ISS. As such, it’s likely that Crew Dragon weighs at least 13 tons with a full crew of four astronauts. It’s possible that SpaceX can reduce Dragon’s mass or eke out more performance from Falcon 9 with a more aggressive booster landing further downrange, allowing the Polaris Dawn crew to narrowly beat the Gemini XI record.
If SpaceX went as far as expending a well-worn Falcon 9 booster for the mission, it’s likely that the mission could double or even triple the altitude record. If, like with Gemini XI, SpaceX launched Crew Dragon into an elliptical orbit, it could likely go even higher and easily beat the Gemini record while still recovering Falcon 9’s first stage.
Beyond the aspirational record-breaking altitude, Polaris Dawn will also debut SpaceX’s custom-built EVA (extra-vehicular activity) spacesuits, which are described as an overall upgrade to and replacement for the intra-vehicular (IVA) suits that already routinely protect NASA and private Dragon astronauts. The Polaris announcement is the first time SpaceX has publicly confirmed that it’s developing its own EVA suit. If it happens as planned, Polaris Dawn will mark the first private/commercial EVA in the history of spaceflight.
Finally, Polaris has plans for not one but three private astronaut launches. The second mission will follow in the footsteps of Polaris Dawn – likely with another Crew Dragon flight, though SpaceX and Polaris haven’t settled on a choice yet. The third mission, however, aims to be the first crewed launch of SpaceX’s next-generation Starship rocket and an essential pathfinder for DearMoon, a separate Starship launch contract that aims to send a crew of artists around the Moon as early as 2023.
A California radiologist who drove his Tesla Model Y off a 250-foot cliff in an attempt to kill his family has had his charges dismissed after doctors say he is “doing well” in a mental health program.
Dharmesh Patel was charged with three counts of attempted murder in connection with a January 2023 crash where he drove his Tesla off a cliff, injuring his wife and two children, aged 7 and 4 at the time.
Patel drove the Tesla off Devil’s Slide in California, an area that is extremely rough to the point that investigators and rescuers expected the worst when arriving at the scene for the first time. Patel supposedly had schizoaffective disorder, according to Deputy District Attorney Dominique Davis.
Shockingly, Patel’s wife, who was in the vehicle, testified that she did not want her husband to be prosecuted, noting that their children missed their father and they wanted him to come back home. Patel’s attorney argued, “not everyone who commits a crime is a criminal.”
Doctor who took Tesla off cliff gets support from unlikely person
A three-day trial in Mental Health Diversion Court ruled in Patel’s favor, which kept him out of jail and instead on house arrest. He was admitted to a Mental Health Diversion Program, which he successfully completed, the Associated Press reported. San Mateo County District Attorney Steve Wagstaffe said the judge was “required by law” to dismiss the charges:
“If the person who’s given mental health diversion follows the treatment plan, there’s nothing that can be done, and at the end of the two years he gets it wiped out of his record.”
Wagstaffe said he has argued, along with other DAs in California, to have attempted murder removed from the list of charges eligible to be dismissed due to mental health diversion programs.
Patel had the charges officially dismissed on Monday; his wife waited for him as he left court and they departed the building together, according to Mercury News. Patel surrendered his California medical license in December.
The crash has been one of the best examples of Tesla’s incredible engineering, which has saved four lives in this particular instance. The car was totalled but kept the four human beings alive and safe, which is something that many referred to as “an absolute miracle.”
A common misconception of anti-EV proponents is that the batteries used in the vehicles are detrimental to the environment and that they cause more waste than they are worth. But a look at Tesla’s battery recycling efforts last year shows the company is doing more than ever to recover materials and give portions of the cells a second life.
Tesla reported a significant milestone in its sustainability efforts last year, with battery recycling volumes rising 20% compared to 2024. According to the company’s 2025 Impact Report, Tesla recycled over 14,000 metric tons of battery material through a combination of in-house processing at its Gigafactories and collaborations with third-party recycling partners.
Tesla: “In 2025, we recycled over 14,000 metric tons of battery material through a combination of in-house processing and through our network of recycling partners.”
That’s equivalent to 46,000 long-range battery packs, a +20% increase from 2024. pic.twitter.com/TC3Nz7Kaqf
— Sawyer Merritt (@SawyerMerritt) July 7, 2026
This amount of recovered material is equivalent to the resources needed to produce approximately 46,000 long-range battery packs. The increase reflects growing operational scale as Tesla’s global vehicle fleet expands and more batteries reach end-of-life or manufacturing scrap becomes available for processing.
Tesla and Battery Recycling
Battery recycling forms a core part of Tesla’s circular economy strategy. The company designs its batteries for longevity, often exceeding 200,000 miles of driving, and prioritizes repairs, remanufacturing, and second-life applications before full recycling.
Once packs are decommissioned, Tesla ensures 100% are recycled with no materials sent to landfills. This approach recovers critical metals including lithium, nickel, cobalt, and copper, which can be refined and reused in new battery production.
Tesla has advanced hydrometallurgical recycling processes capable of achieving recovery rates up to 98% for key battery metals. These methods are more efficient and environmentally friendly than traditional pyrometallurgical techniques, reducing energy use and enabling higher-purity materials suitable for direct reintegration into battery manufacturing.
Tesla co-founder JB Straubel confirms Redwood’s battery recycling operations are already profitable
In-house capabilities are supplemented by a network of specialized partners, creating a robust system that handles both production scrap and end-of-life packs.
The environmental and economic benefits are substantial. Recycling reduces reliance on virgin mining, lowers the carbon footprint associated with raw material extraction and processing, and helps stabilize supply chains for critical minerals amid rising global EV demand. As millions of Tesla vehicles age, the volume of recyclable material is expected to grow significantly in the coming years.
This 20% year-over-year growth demonstrates the effectiveness of Tesla’s investments in recycling infrastructure and technology. It positions the company as a leader in addressing one of the automotive industry’s major sustainability challenges. Continued innovation in battery design for easier disassembly and higher recyclability will further enhance these efforts.
Overall, Tesla’s progress in 2025 highlights how scaling recycling operations supports both environmental goals and long-term business resilience in the transition to electric mobility. As the EV market matures, such closed-loop systems will become increasingly vital for sustainable growth.
Tesla has spent years trying to engineer its way out of the automotive paint shop, one of the most expensive, space-consuming, and environmentally costly steps in vehicle manufacturing. With the Cybercab, Tesla confirmed on X this week that a new reaction injection molding process will embed color directly into the panel itself during production.
“Our new reaction injection molding (RIM) process shrinks Cybercab paint cycles from hours to minutes. This cuts those parts’ manufacturing and supply chain emissions by 35% and eliminating 100% of paint volatile organic compounds (VOCs) emitted in traditional paint methods.” noted Tesla.
While the RIM process isn’t necessarily new and has existed since the 1960s, what makes Tesla’s application notable is how it is being used specifically for exterior body panels that traditionally required a separate paint process after forming.
Tesla’s RIM approach integrates the color directly into the panel material during the molding process itself. The pigment is part of the polymer mix injected into the mold, meaning the panel comes out of the mold already colored, with no separate paint application required. The clear coat or protective layer can be applied at the mold stage or through a much faster post-process than traditional multi-stage painting. Tesla claims this compresses what was a multi-hour paint cycle into minutes per panel.
Tesla’s obsession with killing the paint shop is one of the most consistent threads running through the company’s manufacturing philosophy going back years. As far back as 2018, Musk was trimming paint color options to simplify production, tweeting at the time: “Moving 2 of 7 Tesla colors off menu on Wednesday to simplify manufacturing.” Two years later, in a 2020 Automotive News interview, Musk laid out his broader vision, saying he believed Tesla factories could one day be 1,000 times more efficient than conventional plants, and pointing to the paint shop as one of the biggest sources of waste, cost, and complexity. The Cybertruck was the most extreme expression of that thinking. Tesla chose an unpainted stainless steel exterior partly because it would eliminate the need for a $200 million paint facility at Gigafactory Texas. The stainless approach proved harder and more expensive than anticipated, but the underlying ambition never changed. The Cybercab is what happens when that same ambition meets a manufacturing process that delivers on it.
Radiologist who drove Tesla off cliff has attempted murder charges dismissed
Tesla battery recycling efforts increased 20 percent last year
