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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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Cybertruck

Tesla Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Elon Musk

Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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Elon Musk

SpaceX has solved Starship’s biggest challenge, Elon Musk says

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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