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SpaceX Starlink launch ambitions just saved a space station resupply mission from bigger delays

Thanks to SpaceX's ambitious 2020 launch cadence, the latest Cargo Dragon mission has only been delayed a few days by the need to replace the rocket's second stage. (Richard Angle)

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SpaceX’s ambitious 2020 Starlink launch goals have unintentionally saved a Cargo Dragon spacecraft mission from much longer delays after a major part of its Falcon 9 rocket had to be replaced at the last second.

Known as SpaceX’s 20th NASA Commercial Resupply Services (CRS-20) mission, SpaceX’s Cargo Dragon spacecraft was initially scheduled to launch supplies to the International Space Station (ISS) as early as March 2nd, 2020, a date that recently slipped four days to 11:50 pm EDT (04:50 UTC), March 6th. Simultaneously, a separate Falcon 9 Starlink mission – assigned to a different launch pad – found itself delayed from March 4th to March 11th.

A day or so after news of the CRS-20 launch delay first broke, NASA published a blog post noting that SpaceX had taken the extraordinary step of fully replacing the mission’s Falcon 9 second stage, the part of the rocket (pictured underneath Dragon in the photo above) tasked with taking payloads from the edge of space into Earth orbit (or beyond). Triggered by a faulty component in its space-optimized Merlin Vacuum engine, the fact that SpaceX chose to replace the upper stage and still only delayed CRS-20’s launch by four days suggests that its ambitious Starlink launch plans are already creating positive side effects for commercial customers.

 
The last Cargo Dragon (Dragon 1) capsule expected to launch was likely shipped to Florida earlier this month. (SpaceX)

As of late, multi-day hardware-related launch delays have been rather rare for SpaceX, who has instead suffered numerous weather-related scrubs over the course of completing its Fall 2019 and Winter 2020 launch manifest. SpaceX’s February 17th Starlink-4 mission did suffer a minor second stage valve-related delay that was fixed in about 24 hours, but things have otherwise been quite smooth for Falcon 9.

Given all that goes into building and testing Falcon 9 second stages, there are very few good explanations (aside from pure luck) that would allow for a given SpaceX launch to entirely replace its assigned second stage a week before liftoff and only slip a handful of days. Nevertheless, with CRS-20, SpaceX is attempting to do exactly that.

“SpaceX identified a valve motor on the second stage engine behaving not as expected and determined the safest and most expedient path to launch is to utilize the next second stage in line that was already at the Cape and ready for flight. The new second stage has already completed the same preflight inspections with all hardware behaving as expected. The updated target launch date provides the time required to complete preflight integration and final checkouts.”

NASA.gov — February 25th, 2020

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A Falcon 9 second stage coasting in orbit during SpaceX’s May 2019 Starlink v0.9 mission. (SpaceX)
Falcon 9 has won a contract launch what will likely be a rideshare mission - featuring the Nova C Moon lander - in July 2021. (SpaceX)
A render of a Falcon second stage’s Merlin Vacuum (MVac) engine burning towards orbit as its payload fairing is jettisoned. (SpaceX)

The specific lead times SpaceX’s Falcon rocket family parts require is almost totally unknown but it’s safe to say that the process of building a Falcon upper stage from scratch, performing acceptance testing in Texas, and shipping said stage to the launch pad takes months from start to finish. For SpaceX to be able to attempt to minimize CRS-20’s delays to just four days while still fully swapping out its upper stage, the company would have quite literally had to have had another Falcon stage just sitting around in Florida.

As it turns out, per NASA’s official statement, that is precisely what transpired. A separate second stage was already in Florida and “ready for flight”, giving SpaceX the luxury of selecting the safest option theoretically available. Beyond the hardware already being ready to go in Florida, the stage reassignment almost certainly also hinged upon the mission it was assigned to being somewhat nonessential – a label that SpaceX would be hard-pressed to affix to any of its customers’ launches. An internal Starlink mission, however, would be a perfect opportunity, allowing SpaceX to avoid both picking favorites and seriously impacting (aside from the ~4-day CRS-20 delay) its paying customers.

Pictured landing in July 2019 after its second launch, Falcon 9 booster B1056 - now on its fourth launch - is set to break a crucial reusability record. (SpaceX)
Falcon 9 booster B1059.2 is expected to attempt SpaceX’s first land landing zone recovery of 2020 after launching CRS-20. (SpaceX)

To be clear, SpaceX was thus able to swap out CRS-20’s upper stage at the last second with only a minor schedule impact almost exclusively because of it’s ambitious plans for 20-24 Starlink launches this year. If the company wasn’t pursuing a more than biweekly 2020 launch cadence, it’s much more likely that CRS-20 would have had to make do with its second stage or wait for a new one to be built, potentially delaying the launch by one or two weeks, if not longer.

In simple terms, the launch cadence SpaceX is targeting (and needs) for its Starlink constellation is already exhibiting signs of a future where its high-performance orbital-class rockets have been almost entirely commodified.

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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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Elon Musk

Elon Musk shuts down talk of TSMC taking over Terafab

Musk says Tesla and SpaceX will build and run Terafab, with TSMC limited to renting.

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SpaceX Terafab rendering

Elon Musk has drawn a firm line around who will be in charge of Terafab, the giant chip factory Tesla and SpaceX are planning in Texas.

Musk replied to a post on X arguing that Taiwan Semiconductor Manufacturing Company (TSMC) would most likely end up owning and operating the plant. “No, we will build and run the fab. Let there be ZERO doubt about that,” Musk wrote. “Maybe TSMC subleases part of the Terafab if they want, but nothing more than that.”

In plain terms, a sublease means TSMC could rent a section of the complex to make chips, similar to a tenant renting one floor of an office tower. The building, the equipment decisions and the daily operation would stay with Tesla and SpaceX.

The comment shuts down speculation that started last week. On October 2, tech journalist Tim Culpan reported that TSMC was exploring ways to help run Terafab’s factories. Musk responded the next day that it was “just discussions, but something may come of it,” as Teslarati reported at the time. That left room for a scenario where the world’s largest contract chipmaker took the wheel. Musk’s latest post closes that door.

Elon Musk teases TSMC as potential Terafab partner

Some background helps explain why this matters. Tesla designs its own AI chips today but pays outside companies like TSMC and Samsung to manufacture them. Musk unveiled Terafab in March as a joint project between Tesla, SpaceX and xAI, arguing that existing suppliers cannot expand fast enough to meet his companies’ future demand. The goal is to produce enough chips each year to supply one terawatt of computing power, roughly 50 times what the entire global AI chip industry produces now.

Those chips are meant for Tesla’s Optimus humanoid robots, the Cybercab and Full Self-Driving computers, along with chips for SpaceX’s planned data centers in orbit. Owning the factory means Musk’s companies would not have to compete with every other chip customer for time on someone else’s production lines.

Intel is still part of the picture. The company signed on in April to help design, build and package chips for the project, and CEO Lip-Bu Tan told Bloomberg this week that Intel will keep working on Terafab despite the TSMC chatter.

The project moved from concept to construction planning over the summer. In August, SpaceX confirmed the Grimes County site about an hour from Houston, sent the county a $10 million payment under its tax abatement deal and said civil work would begin shortly. The first phase carries a $16.8 billion price tag, and total spending across all phases could reach as much as $119 billion.

TSMC chairman C.C. Wei has said a new fab typically takes two to three years to build and another one to two years to reach full output. Tesla and SpaceX have never run one, which is why TSMC’s expertise drew so much attention. Musk’s answer suggests he would rather learn that process in house than hand control of a project this central to Tesla’s robotics and autonomy plans to an outside company.

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Elon Musk

Trump to hand Elon Musk a top honor that traces back to JFK

Trump will award Elon Musk the National Medal of Science at Thursday’s White House summit.

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elon musk and donald trump in front of a tesla cybertruck at the white house

Elon Musk is set to receive the highest honor the U.S. government gives to scientists and engineers.

President Donald Trump will present Musk with the National Medal of Science on Thursday at the White House’s Science: A New Golden Age Summit, Fox News Digital first reported on Wednesday. Google cofounder Sergey Brin, Nvidia CEO Jensen Huang and AMD CEO Lisa Su will receive the same medal, while Dell Technologies CEO Michael Dell and Microsoft CEO Satya Nadella will receive the National Medal of Technology and Innovation. A White House official later confirmed the list to Reuters.

“The Trump administration is grateful for the contributions of these incredible leaders in science and technology. These recipients are helping ensure America keeps leading the world in innovation,” White House spokesperson Liz Huston told Fox News.

It will be the first time Trump has presented either medal in his two terms. Congress created the National Medal of Science in 1959, and the National Science Foundation, which administers it, says 529 scientists and engineers have received it since. A presidential committee reviews nominees, but the president makes the final call.

Thursday’s group of medalists run or founded companies, and three of them sit at the center of the Super Intelligence hardware race that Musk competes in. Huang’s Nvidia supplies the GB300 chips filling SpaceX’s Colossus 2 cluster, while Su’s AMD is Nvidia’s biggest rival in data center GPUs.

Worth noting that Trump’s uncle, MIT physicist John G. Trump, received the National Medal of Science from President Ronald Reagan for his work on ionizing radiation and its uses in medicine and industry.

The Pentagon taps Elon Musk to design the battlefield of the future

For Musk, the medal is the latest sign of how far his relationship with Trump has come since their 2025 split over the “Big Beautiful Bill” and his exit from DOGE. Last week, he sat at Trump’s left during a White House lunch where AI executives signed a voluntary safety accord, and Defense Secretary Pete Hegseth named him to help lead the Pentagon’s Project Meridian study on the future of warfare. Musk has also adopted the administration’s new vocabulary, saying on Sunday that SpaceXAI will be renamed SpaceXSI after Trump ordered federal agencies to replace “artificial intelligence” with “super intelligence.”

Musk has collected science honors before, including the Stephen Hawking Medal for Science Communication in 2019.

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Tesla FSD changed its mind mid-intersection, and it may have saved a life

Tesla shares dashcam footage of FSD Supervised stopping mid intersection to avoid a T-bone crash.

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Credit: @BLKMDL3/X

Tesla is putting another Full Self-Driving save in front of its 24.8 million followers on X.

On Tuesday morning, Tesla’s main account shared a dashcam clip with the caption “FSD Supervised preventing T-bone crash.” The footage came from an owner posting as TheNewGrid, who described what happened at a stop sign: “I looked at the car coming to the stop sign figured they would stop, my car went, then came to a stop mid intersection as they flew by. Had I been manually driving this would have resulted in a crash.”

The sequence is the notable part. FSD had already started crossing when the other driver ran the stop sign. Instead of pressing on, the car braked hard in the middle of the intersection and let the crossing vehicle pass in front of it. By the owner’s own account, they had made the same assumption the software initially made, that the other car would stop, and would not have corrected in time.

The clip is the latest in a run of safety posts Tesla has amplified over the past several days. On Saturday, the company shared a video from Selling Sunset star Jason Oppenheim, who sold his Bentley for a Model Y and said he was buying Teslas with FSD for 10 of his employees. Ashok Elluswamy, who leads Tesla AI, followed up by writing that Tesla self-driving “reacts to other people cutting into your path with super-human response times.” On Monday, a Cybertruck owner posted footage of FSD moving across three lanes from a red light to clear a path for an ambulance approaching from behind.

This recent clip also lands a few weeks after Tesla began shipping Automatic Collision Evasion with FSD v14.3.9, a feature that can activate FSD on the driver’s behalf when a frontal collision is imminent or the driver appears distracted. Elluswamy said in September that “even earlier prediction of hazards, even faster reaction time and overall significantly better safety and collision avoidance” are coming with v15, the release Tesla has tied to round the clock Robotaxi operation.

The safety messaging matters beyond social media. Tesla has said FSD Supervised was 4.1 times less likely to crash than manual driving across 100 million kilometers on European roads, and it has been putting those figures in front of regulators. Eight EU countries have now approved FSD Supervised, with Croatia the most recent, but the EU’s bloc-wide vote originally set for October 6 has been pushed to December at the earliest.

FSD Supervised is still a Level 2 system, and the driver remains responsible at all times. Even heavy users find reasons to step in. Teslarati’s Joey Klender, who uses FSD for about 76 percent of his driving, laid out five recurring issues on Tuesday that still prompt him to intervene. Clips like this one show the other column of that ledger: moments where the software caught a mistake a human was about to make.

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