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Crew Dragon is lifted off the deck of SpaceX recovery vessel GO Searcher after safely arriving at Port Canaveral, March 10th. (NASA) Crew Dragon is lifted off the deck of SpaceX recovery vessel GO Searcher after safely arriving at Port Canaveral, March 10th. (NASA)

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SpaceX’s Crew Dragon explosion investigation almost complete, says executive

Crew Dragon C201 is lifted off the deck of a SpaceX recovery vessel on March 10th. C201 was destroyed in an explosion on April 20th. (NASA)

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Speaking at the 2019 AIAA Propulsion & Energy Forum, SpaceX Vice President of Build and Flight Reliability Hans Koenigsmann was significantly more confident that the company is just days or weeks away from wrapping up a serious Crew Dragon failure investigation.

On April 20th, flight-proven Crew Dragon capsule C201 experienced a catastrophic failure mode – largely a surprise to SpaceX – that completely destroyed the vehicle milliseconds prior to a planned static fire test. Given the obvious mortal danger such a failure would have posed to any crew aboard, SpaceX’s plans to conduct its first crewed Crew Dragon launch (Demo-2) in Q3 2019 were thrown out the window. Thankfully, Hans believes that SpaceX is just shy of concluding that investigation, “hopefully” permitting the launch of a critical abort test and Demo-2 before 2019 is out.

More specifically, Koenigsmann noted that SpaceX is currently planning to conduct a critical Crew Dragon in-flight abort (IFA) test in October or November, more or less in line with a recent report from NASASpaceflight.com that the test is targeted for November 11th, 2019. NASASpaceflight also confirmed that SpaceX still plans to fly Falcon 9 booster B1046.3 on the critical test flight, currently the only established plan to launch a thrice-flown booster, a potential first for SpaceX’s reusability program.

SpaceX’s IFA test is a continuation of the company’s suborbital Crew Dragon testing. Back in 2015, SpaceX successfully completed a pad abort test in which a low-fidelity Dragon mockup used its eight SuperDraco abort thrusters to replicate an escape from a rocket failure on the launch pad. SpaceX’s in-flight abort test will – like its namesake indicates – perform a similar test in flight, ensuring that Crew Dragon is able to safely escape from a failing Falcon 9 at Max Q, the point during launch where atmosphere-induced mechanical stress is at its peak.

In theory, demonstrating a successful pad and in-flight (Max Q) abort means that a given spacecraft is able to safely abort at all points during flight – from the pad all the way to orbit. It’s not clear if Crew Dragon is actually designed to be capable of what’s known as an “abort-to-orbit”, but the hardware is likely there if it’s needed.

Crew Dragon approaches the ISS during its orbital launch debut, March 3rd. (NASA)

On July 15th, Hans Koenigsmann and NASA Commercial Crew Program (CCP) manager Kathy Lueders went into significant detail with a preliminary Crew Dragon failure investigation update. They revealed that Crew Dragon’s April 20th explosion was traced to a likely mode, in which a “slug” of Dragon’s liquid oxidizer (nitrogen tetroxide, NTO) leaked and was subsequently smashed into a titanium valve by helium pressurized to several thousand PSI.

Said impact – effectively turning NTO into a bullet – thus created a spark in one or two ways: the titanium debris could have easily created sparks on its own, while NTO is also known to interact in violent and exotic ways with titanium under impact conditions. Either way, the fix is relatively simple (replace the valves and avoid titanium in the NTO pressurization system), but the fact that the design flaw existed in the first place serves as a much larger concern for the entirety of Crew Dragon’s joint SpaceX-NASA design and certification.

Ultimately, Hans seemed much more confident on August 19th than he was a month prior, indicating that the investigation is just shy of wrapping up. Once complete, SpaceX can complete the necessary modifications and get back on the saddle for Crew Dragon’s inaugural crewed launch and next abort test.

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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 Giga Berlin makes a statement of solidarity amid IG Metall conflict

The display comes as tensions between Tesla and IG Metall continue to escalate.

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Creidt: Andre Thierig/X

Tesla Giga Berlin is sending a strong message of solidarity amid its ongoing legal dispute with German union IG Metall.

In a post on social media platform X, Giga Berlin plant manager André Thierig shared an image of the facility’s lobby covered with a large banner that reads: “Progress. Innovation. Success.” He added that the slogan reflects what the facility has stood for since Day One.

“Our lobby at Giga Berlin covered in a huge banner these days. Progress. Innovation. Success – this is what we stand for since we started production in 2022 and how we will go into our future!” Thierig wrote in his post on X. 

The display comes as tensions between Tesla and IG Metall continue to escalate.

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The dispute began after Tesla accused a union representative of secretly recording a works council meeting at Giga Berlin. Tesla stated that it filed a criminal complaint after the alleged incident. Police later confirmed they had seized a computer belonging to an IG Metall member as part of their investigation.

“What has happened today at Giga Berlin is truly beyond words! An external union representative from IG Metall attended a works council meeting. For unknown reasons he recorded the internal meeting and was caught in action! We obviously called police and filed a criminal complaint!” Thierig wrote on X at the time

IG Metall denied the accusation and characterized Tesla’s move as an election tactic ahead of upcoming works council elections. The union subsequently filed a defamation complaint against Thierig. Authorities later confirmed that an investigation had been opened in connection with the matter.

Giga Berlin began production in 2022 and has since become one of Tesla’s key European manufacturing hubs, producing the Model Y for regional markets. The facility has expanded capacity over the past years despite environmental protests, labor disputes, and regulatory scrutiny.

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Tesla Megapack Megafactory in Texas advances with major property sale

Stream Realty Partners announced the sale of Buildings 9 and 10 at the Empire West industrial park, which total 1,655,523 square feet.

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Credit: Tesla

Tesla’s planned Megapack factory in Brookshire, Texas has taken a significant step forward, as two massive industrial buildings fully leased to the company were sold to an institutional investor.

In a press release, Stream Realty Partners announced the sale of Buildings 9 and 10 at the Empire West industrial park, which total 1,655,523 square feet. The properties are 100% leased to Tesla under a long-term agreement and were acquired by BGO on behalf of an institutional investor.

The two facilities, located at 100 Empire Boulevard in Brookshire, Texas, will serve as Tesla’s new Megafactory dedicated to manufacturing Megapack battery systems.

According to local filings previously reported, Tesla plans to invest nearly $200 million into the site. The investment includes approximately $44 million in facility upgrades such as electrical, utility, and HVAC improvements, along with roughly $150 million in manufacturing equipment.

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Building 9, spanning roughly 1 million square feet, will function as the primary manufacturing floor where Megapacks are assembled. Building 10, covering approximately 600,000 square feet, will be dedicated to warehousing and logistics operations, supporting storage and distribution of completed battery systems.

Waller County Commissioners have approved a 10-year tax abatement agreement with Tesla, offering up to a 60% property-tax reduction if the company meets hiring and investment targets. Tesla has committed to employing at least 375 people by the end of 2026, increasing to 1,500 by the end of 2028, as noted in an Austin County News Online report.

The Brookshire Megafactory will complement Tesla’s Lathrop Megafactory in California and expand U.S. production capacity for the utility-scale energy storage unit. Megapacks are designed to support grid stabilization and renewable-energy integration, a segment that has become one of Tesla’s fastest-growing businesses.

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Tesla Sweden strikers see tax issues over IF Metall union error

To address the issue, IF Metall is encouraging Tesla strikers to return the refunded tax amounts to the union.

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Credit: Tesla Europe

A tax correction is set to return two years of income tax payments to Tesla strikers in Sweden, after authorities determined that conflict compensation during a labor dispute should not have been taxed.

The issue is caused by a decision by IF Metall to treat strike compensation for Tesla workers as taxable income during the ongoing labor dispute with Tesla Sweden. That approach has now been reversed following guidance from the Swedish Tax Agency.

Strike compensation is typically tax-free under Sweden’s Income Tax Act, as noted in a report from Dagens Arbete (DA). However, two years ago, IF Metall’s board decided to classify payments to Tesla strikers as taxable.

“We did it to secure SGI, unemployment insurance and public pension. Those were the risks we saw when the strike had already dragged on,” Kent Bursjöö, financial manager at IF Metall, stated.

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According to Bursjöö, the union wanted to ensure that members continued to register earned income with the tax agency, protecting benefits tied to income history. At the end of January, however, the Swedish Tax Agency informed the union that compensation during a labor dispute must be tax-free.

“Of course, we knew that it could be tax-free. But we clearly didn’t know that it couldn’t be taxable,” Bursjöö said.

Following discussions with auditors and tax authorities, IF Metall began correcting the payments. As a result, two years of paid income tax will now be credited back to the affected strikers’ tax accounts. The union will also recover previously paid employer contributions.

However, the correction creates secondary effects. Since the payments will now be treated as tax-free, pension contributions tied to those earnings will be withdrawn, potentially affecting state pension accrual and income-based benefits such as parental or sickness benefits.

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To address this, IF Metall is encouraging members to return the refunded tax amounts to the union. In exchange, the union plans to pay 18.5% into occupational pensions on their behalf. “Otherwise, it will be a form of overcompensation when they get the tax paid back,” Bursjöö said.

That being said, the IF Metall officer acknowledged that the union’s legal ability to reclaim the funds from its improperly paid Tesla Sweden strikers is limited. “The legal possibilities are probably limited, from what we can see. But we assume that most people see the value of securing their pension,” Bursjöö said.

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