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Space Force officials say the Falcon 9 booster pictured here in SpaceX's rocket factory will have to wait a few months longer for its launch debut. (SpaceX) Space Force officials say the Falcon 9 booster pictured here in SpaceX's rocket factory will have to wait a few months longer for its launch debut. (SpaceX)

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SpaceX’s third NASA astronaut launch to reuse Crew Dragon and Falcon 9

The next new Falcon 9 SpaceX launches could become the first orbital-class liquid rocket in history to fly astronauts twice. (SpaceX)

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NASA has revealed that SpaceX could reuse the next Falcon 9 booster and first Crew Dragon spacecraft scheduled to launch astronauts as soon as SpaceX’s third astronaut launch, scheduled for early 2021.

First, though, SpaceX must successfully return two NASA astronauts to Earth just a few days from now and launch another four astronauts – three NASA and one Japanese (JAXA) – to the International Space Station (ISS) just ~8 weeks later. Astronauts Bob Behnken are currently occupying the ISS as part of Crew Dragon’s inaugural crewed launch, which has been a near-flawless success up to this point. Those astronauts are scheduled to board the orbiting spacecraft and depart the ISS on August 1st and reenter Earth’s atmosphere roughly one day later on August 2nd.

It will be Crew Dragon’s second orbital reentry but also its first with astronauts aboard. If Crew Dragon performs as designed and capsule C206 is recovered without issue, SpaceX and NASA will debrief all teams involved, inspect the spacecraft and astronaut spacesuits, and hopefully certify the spacecraft for operational crewed launches.

Falcon 9 B1061, the booster NASA refers to above, arrived in Florida on July 14th ahead of SpaceX’s second astronaut launch ever. (SpaceX)

Mentioned above, the first of those operational astronaut launches will be known as Crew-1 or Post-Certification Mission 1 (PCM-1) and is currently expected to launch no earlier than (NET) late September. Crew-1’s launch date is almost entirely contingent upon the successful completion of Demo-2 and NASA’s subsequent certification of Crew Dragon. SpaceX is in the process of delivering all the rocket and spacecraft hardware needed for Crew-1 from its Hawthorne, California factory to launch and processing facilities at Cape Canaveral, Florida and Kennedy Space Center (KSC).

Believed to be capsule C207, the Crew Dragon spacecraft pictured here in May 2020 is assigned to Crew-1. (SpaceX)
In a major twist, NASA has effectively confirmed that SpaceX will become the first private company in history to launch astronauts into orbit. (SpaceX)
The Demo-2 Crew Dragon spacecraft arrived in Florida roughly 3.5 months before launch.(SpaceX)

New Falcon 9 booster B1061 completed a suite of acceptance tests at SpaceX’s McGregor, Texas development facilities between April and June 2020 and ultimately shipped from Texas to Florida on July 11th, arriving on July 14th. A new Falcon 9 upper stage is likely close behind the booster and SpaceX will be able to begin integrated processing, culminating in a preflight wet dress rehearsal (WDR) and static fire a few weeks prior to launch.

An expendable trunk and the new Crew Dragon capsule assigned to Crew-1 – believed to be capsule C207 – could arrive at SpaceX’s Cape Canaveral Air Force Station (CCAFS) processing facilities any day now. Prior to heading to Florida, the spacecraft must complete numerous acceptance tests, including hardware-in-the-loop launch simulations, the static fire of all four SuperDraco abort thruster modules and Draco maneuvering pods, a from of WDR, and more. After arriving, SpaceX will inspect every part of the spacecraft, complete any final outfitting needed, load the capsule with monomethylhydrazine (MMH) fuel and dinitrogen tetroxide (NTO) oxidizer, and install its trunk section.

Crew Dragon C206 was installed on its trunk by May 1st, one month prior to launch. (SpaceX)
Crew Dragon C206 was photographed in orbit by one of the astronauts that piloted it during a July 1st spacewalk. (NASA)

If Demo-2 Crew Dragon capsule C206 is able to safely return astronauts Behnken and Hurley to Earth and make it back to dry land in one piece, it could become the first American space capsule in history to launch astronauts into orbit twice. The same goes for Crew-1 Falcon 9 booster B1061: if it successfully launches and lands as part of SpaceX’s operational astronaut launch debut, it will be refurbished to become the first liquid rocket booster in the world to support two astronaut launches when it flies again on Crew-2.

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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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Google just picked SpaceX for its first step into orbital AI

Google will launch its first Project Suncatcher AI satellite on SpaceX’s Transporter-18 rideshare next week.

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Google is about to put its own AI chips into orbit for the first time, and it is paying SpaceX to get them there.

The company said Thursday that the first in-orbit test of Project Suncatcher, its research effort to find out whether space can host large-scale AI computing, will fly next week on SpaceX’s Transporter-18 rideshare mission.

The satellite, called MVP, is about the size of a refrigerator and carries four of Google’s Tensor Processing Units, the same chips Google runs in its ground data centers. Google originally planned to launch two custom satellites in 2027, but chose to move faster by integrating its chips into a satellite.

MVP’s solar panels supply about one kilowatt of power, and Google will run Gemini models on the TPUs only in bursts of roughly 15 minutes before the chips shut down so the radiators can shed heat. In a blog post, Google said its Trillium TPUs survived vibration testing that mimicked sustained launch loads of up to 10g, with individual components seeing 50 to 100g, and handled a radiation dose greater than a five year mission would deliver.

SpaceX and Google mull massive partnership on Musk’s orbital data dream: report

Next week’s flight, slated for October 1, follows a relationship that became public in May, when Teslarati reported that Google was in talks with SpaceX for a launch deal tied to orbital data centers. Google also holds a stake of roughly 6% in SpaceX.

The two companies are chasing the same idea from very different starting points. SpaceX’s own orbital compute program is built around the AI1 satellite, a roughly 70 meter structure derived from Starlink V3 hardware that is designed for 150 kW of peak compute, about 150 times the power MVP will draw. Elon Musk has brushed off concerns about crowding orbit with those satellites, and SpaceX is building its Gigasat factory in Bastrop, Texas, to produce them, targeting an annualized rate of about 1 GW of space compute by the end of 2027.

Musk also posted on X on Thursday that “the amount of compute in space will obviously round up to 100% of all compute.”

Google has been more cautious in public. Its research estimates that launch prices need to fall below about $200 per kilogram before an orbital data center can compete with a ground facility on energy cost, a threshold the company believes could be reached around the mid 2030s. The Suncatcher team has said it expects the effort to remain a project rather than a product for years, which leaves the first real test of its hardware riding on a rocket from the company with the most aggressive timeline in the field.

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Tesla Cybercab gets initial tie-in to localized, in-house cathode plant

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Credit: Tesla

Tesla has taken another concrete step toward owning its battery supply chain, and it’s doing so with what is perhaps the most important vehicle in its short-but-storied history.

On September 23, Tesla announced that it has officially built the first Cybercab with cathode material produced in-house at the company’s first cathode plant in the U.S., and the first in the U.S. overall.

Active cathode material is the most expensive piece of a lithium-ion battery cell, and it often accounts for more than a third of cell cost. For years, the industry sourced a majority of it from Asia, but Tesla’s decision to make it in the United States bodes well for the Cybercab project. This is the latest chapter in Tesla’s vertical integration strategy, which began in public at Battery Day in 2020.

At the Battery Day Event, Elon Musk said the company would build a North American cathode plant and overhaul the process to cut costs and waste, while also making some of the most powerful and long-lasting cells in the industry.

The Austin facility took years to appear. Tesla filed permits for “Project Cathode” in 2022 on land near Giga Texas. By mid-2022, the building frame was up and Tesla later invested hundreds of millions of dollars as part of a larger expansion of the Giga Texas plant. The company stated it was operating the first large-scale cathode production facility in North America to supplement 4680 cell production.

One month later, that material reached a finished Cybercab.

The timing of this breakthrough is monumental for the Cybercab program. As Tesla officially launched the first Cybercab rides to the public earlier this month, production of the ride-hailing-geared vehicle is moving forward on the planned S-curve that CEO Elon Musk told everyone to expect.

Nevertheless, packs of Cybercab units have been spotted throughout the United States, in an effort to potentially activate the fleet as soon as the company gains regulatory approval in various geographic areas.

On top of that, Tesla owning the cathode step and pairing it with its own in-house lithium from the Gulf Coast refinery shortens the supply chain that once stretched thousands of miles and subjects every pack to fewer external price shocks and geopolitical risks.

Tesla is not yet independent of all of its foreign suppliers, as some precursor metals come from mines and chemical plants. But the first in-house cathode Cybercab shows the company is closing the most expensive and most concentrated gap in its battery production efforts. For a vehicle like Cybercab to operate at a high utilization within the Robotaxi network, that control over cost is so crucial.

It is arguably as important as the software that drives it.

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Tesla leaks Semi customers ahead of handover event

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Credit: Tesla

Tesla is set to inaugurate its dedicated Semi factory in Sparks, Nevada, this evening, but drone footage has already started to show who is expected on the handover stage.

Zanegler, a drone operator who regularly documents Tesla Semi operations in Nevada, filmed a row of new-generation Semi units parked outside of the plant with customer branding applied. The liveries visible in the video include companies like PepsiCo, U.S. Foods, Einride, DHL, WattEV, and others that have committed to utilizing Tesla’s Class 8 electric truck in their fleets.

Several of those company names already sit within Tesla’s public ordering book, including PepsiCo, which has been the program’s primary anchor customer since the first Semi deliveries in December 2022. PepsiCo now runs dozens of Tesla Semi units in daily service, with drivers completing regional routes.

Einride placed a 500-unit order in August, which was, at the time, the largest single Semi commitment. First deployments of their Semi units are planned for this month and will eventually span across California, Texas, New Jersey, Illinois, and Georgia. Meanwhile, IMC Logistics announced a 50-truck California order this week.

Tesla Semi lands the biggest electric truck deal in U.S. history

Other names, like LTS, OK Produce, and HMD, have not been widely confirmed as firm buyers, but their presence on the lot is perhaps the clearest signal that Tesla intends to expand on that list this evening at the event.

Tesla first unveiled the Semi back in 2017 with a 2019 production target.

Limited pilot builds reached PepsiCo in late 2022, and high-volume production began at the new 1.7-million-square-foot plant that sits logically positioned next to Tesla’s Gigafactory Nevada. Tesla Semi program director Dan Priestley has said that Tesla expects to build “many thousands” of Semi units this year, but as with every Tesla release, there have been set expectations of an S-curve ramp.

Outside estimates still put 2026 deliveries in the 5,000-to-15,000 range, but it will ultimately depend on Tesla’s readiness to put those units out, as well as how smoothly production is moving internally.

Tesla’s Semi Rollout event is set to start tonight at the Sparks factory, and it will be livestreamed on X starting at 6 p.m. PDT / 9 p.m. ET.

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