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SpaceX considers second Crew Dragon launch pad to reduce risk from Starship

NASA is worried that Crew Dragon's only launch pad could be rendered unusable by an exploding Starship. (Richard Angle/SpaceX)

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Reuters reports that SpaceX has proposed modifying a second Florida launch pad to support Crew Dragon missions after NASA raised concerns about the threat posed by plans to launch Starship out of the only pad currently certified for Dragon.

After more than a year of downtime, SpaceX restarted the construction of an orbital Starship launch site at NASA’s Kennedy Space Center LC-39A pad in late 2021. SpaceX has leased Pad 39A since 2014 and conducted 49 Falcon rocket launches out of the facility since its first use in 2017. Prior to SpaceX’s lease, Pad 39A supported 82 Space Shuttle launches from 1981 to 2011 and every Apollo Program launch to the Moon in the 1960s and 1970s, making it one of the most storied and well-used launch sites in the history of US spaceflight.

In 2018, Pad 39A began supporting launches of SpaceX’s Falcon Heavy, which was and still is the most powerful and capable rocket currently in operation. In May 2020, a Falcon 9 rocket and Crew Dragon spacecraft lifted off with two NASA astronauts in tow, marking SpaceX’s first human spaceflight and the United States’ first domestic astronaut launch of any kind since 2011. The next era of the historic pad could include Starship, a fully-reusable two-stage rocket that SpaceX has been developing in earnest since the mid-2010s. However, NASA is worried that a failure of that immense and unproven rocket could almost instantly destroy what is currently the only launch pad on Earth capable of launching the space agency’s astronauts to the International Space Station (ISS).

One certainly can’t blame NASA for worrying. In its latest iteration, SpaceX’s Starship 39A launch mount will sit roughly 1000 feet (~300m) East of Pad 39A’s existing Falcon launch facilities, which include a tower and arm that are needed for astronauts and cargo to access and board Crew and Cargo Dragons. The Starship mount is also around 1600 feet (~500m) northeast of Pad 39A’s lone horizontal integration hangar, without which Falcon launch operations would become far more difficult or even impossible.

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For the Falcon pad and tower, there is a slight consolation: Starship’s own skyscraper-sized launch tower will be located directly between those Falcon facilities and Starship before and during launches and could partially protect them from any hypothetical blast. The hangar will be fully unprotected, however.

The result of Starship SN9 exploding while nearly empty of flammable propellant. (SpaceX)
At liftoff, a fully-stacked Starship will hold more than three thousand tons of propellant. (SpaceX)

NASA is worried that if a Starship fails before or shortly after launch and explodes at or near its adjacent launch mount, it could destroy or damage the infrastructure the space agency and SpaceX need to launch Crew Dragon to the International Space Station (ISS). At the moment, Boeing – NASA’s second Commercial Crew partner – is likely a year or more away from its first operational astronaut launch, during which Falcon 9 and Crew Dragon will remain a single point of failure that could theoretically sever the space agency’s connection to its own space station at any moment.

In response to NASA’s concern, NASA executive Kathy Lueders – in an interview with Reuters – says that SpaceX has begun working with the agency on plans to both “harden” Pad 39A and modify its Cape Canaveral Space Force Station (CCSFS) LC-40 pad to support Dragon launches. According to Reuters, however, receiving approval to put those plans into action “could take months.” Depending on how significant the facilities LC-40 would need are, there’s also a chance that SpaceX would need to complete a new FAA environmental review to construct a crew access tower.

Pad 39A’s Starship facilities are visible on the left in April 2022. SpaceX has made major progress in the last two months, wrapping up concrete work on the launch tower base and installing all six of the Starship launch mount’s legs. (SpaceX)

Meanwhile, Pad 39A is also the only launch pad in the world capable of supporting Falcon Heavy, which has also become an extremely important rocket for uncrewed NASA spacecraft launches, NASA’s plans to get cargo to its lunar Gateway space station, and to the US military. Modifying one of SpaceX’s other pads to support Falcon Heavy would likely be even harder and take even longer than adding Crew Dragon capabilities to LC-40. In both cases, it’s likely that NASA and the US military would strongly prefer – if they don’t eventually outright require – that SpaceX have backup options already constructed and ready to go before risking the destruction of Pad 39A with its first Starship launch.

39A’s Starship facilities could easily require another 6-12 months of work before they’ll be ready for launch, however, leaving a good amount of time for SpaceX to alleviate the concerns of its US government customers before they might actually start to disrupt plans for East Coast Starship launches.

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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 VP explains latest updates in trade secret theft case

Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

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tesla 4680
Credit: Tesla Inc.

Tesla Vice President Bonne Eggleston explained the latest updates in a trade secret theft case the company has against a former manufacturing equipment supplier, Matthews International.

Back in 2024, Tesla had filed a lawsuit against Matthews International, alleging that the firm stole trade secrets about battery manufacturing and shared those details with some of Tesla’s competitors.

Early last year, a U.S. District Court Judge denied Tesla’s request to block Matthews International from selling its dry battery electrode (DBE) technology across the world. The judge, Edward Davila, said that the patent for the tech was due to Matthews’ “extensive research and development.”

Tesla is suing a former supplier for trade secret theft

The two companies’ relationship began back in 2019, as Tesla hired Matthews to help build the equipment for its 4680 battery cell. Tesla shared confidential software, designs, and know-how under strict secrecy rules.

Fast forward a few years, and Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

Now, the latest twist, as this month, a Judge issued a permanent injunction—a court order banning Matthews from using certain stolen Tesla parts or designs in their machines. Matthews is also officially “liable” for damages. The exact amount would still to be calculated later.

Bonne Eggleston, a VP for Tesla, said on X today that Matthews is a supplier who “exploited customer IP through theft or deception,” and has no place in Tesla’s ecosystem:

Tesla calls this a big win and warns other companies: “Buyer beware—don’t buy from thieves.”

Matthews hit back with a press release claiming victory. They say an arbitrator ruled they can keep selling their own DBE equipment to anyone and rejected Tesla’s request for a total sales ban. They call Tesla’s claims “nonsense” and insist their 20-year-old tech is independent. Both sides are spinning the same narrow ruling: Matthews can sell their version, but they’re blocked from using Tesla’s specific secrets.

What are Tesla’s Current Legal Options

The case isn’t over—it’s moving to the damages phase. Tesla can:

  • Push forward in court or arbitration to calculate and collect huge financial penalties (potentially $1 billion+ if willful theft is proven).
  • Enforce the permanent injunction with contempt charges, fines, or even jail time if Matthews violates it.
  • Challenge Matthews’ new patents that allegedly copy Tesla’s work, asking courts to invalidate them or add Tesla as co-inventor.
  • Seek extra damages, lawyer fees, and possibly punitive awards under the federal Defend Trade Secrets Act and California law.

Tesla could also refer evidence to federal prosecutors for possible criminal trade-secret charges (rare but serious). Settlement is always possible, but Tesla’s fiery public response suggests they want full accountability.

This isn’t just corporate drama. It shows why trade secrets matter even when Tesla open-sources some patents, confidential know-how shared in trust must stay protected. For the EV industry, it’s a reminder: steal from your biggest customer, and you risk losing everything.

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Tesla Cybercab includes this small but significant feature

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

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Credit: Tesla

Tesla Cybercab manufacturing is strikingly close, as the company is still aiming for an April start date. But small and significant features are still being identified for the first time as production units appear all over the country for testing and for regulatory events, like one yesterday in Washington, D.C.

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

This was for everyone, including the disabled, who are widely reliant on ride-sharing platforms, family members, and medical shuttles for transportation of any kind. Cybercab aims to change that, and Tesla evidently put a focus on those riders while developing the vehicle, evident in a small but significant feature revealed during its appearance in the Nation’s Capital.

Tesla Cybercab display highlights interior wizardry in the small two-seater

Tesla has implemented Braille within the Cybercab to make it easier for blind passengers to utilize the vehicle. On both the ‘Stop/Hazard Lights’ button and the Door Releases, Tesla has placed Braille so that blind passengers can navigate their way through the vehicle:

This is a great addition to the Cybercab, especially as Full Self-Driving has been partially pointed at as a solution for those with disabilities that would keep them from driving themselves from place to place.

It truly is a great addition and just another way that Tesla is showing they are making this massive product inclusive for everyone out there, including those who have not been able to drive due to not having vision.

The Cybercab is set to enter mass production sometime in April, and it will be responsible for launching Tesla’s massive plans for an autonomous ride-sharing program.

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Elon Musk

Tesla and xAI team up on massive new project

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

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Credit: Grok

Elon Musk teased a massive new project, to be developed jointly by Tesla and xAI, called “Digital Optimus” or “Macrohard,” the first development under Tesla’s investment agreement with xAI.

Musk announced on X that Digital Optimus will “be capable of emulating the function of entire companies.”

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

Essentially, it will be an AI version of a desk worker in many capacities, including accounting, HR tasks, and others.

Musk said:

“Grok is the master conductor/navigator with deep understanding of the world to direct digital Optimus, which is processing and actioning the past 5 secs of real-time computer screen video and keyboard/mouse actions. Grok is like a much more advanced and sophisticated version of turn-by-turn navigation software. You can think of it as Digital Optimus AI being System 1 (instinctive part of the mind) and Grok being System 2. (thinking part of the mind).”

Its key applications would be used for enterprise automation, simulating entire companies, high-volume repetitive tasks, and potentially, future hybrid use with the Optimus robot, which would handle physical tasks, while Digital Optimus would handle the clerical work.

Tesla announces massive investment into xAI

The creation of a digital AI suite like Digital Optimus would help companies save time and money, as well as become more efficient in their operations through massive scalability. However, there will undoubtedly be concerns from people who are skeptical of a fully-integrated AI workhorse like this one.

From an energy consumption perspective and just a general concern for the human workforce, these types of AI projects are polarizing in nature.

However, Digital Optimus would be a great digital counterpart to Tesla’s physical Optimus robot, as it would be a hyper-efficient addition to any company that is looking for more production for less cost.

Musk maintains that there is no other company on Earth that will be able to do this.

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