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SpaceX’s first thrice-flown Cargo Dragon returns from orbit with Starship tiles intact
After a flawless reentry and splashdown on August 27th, SpaceX’s first thrice-flown Cargo Dragon spacecraft completed its latest mission, arriving in Port of Los Angeles aboard SpaceX vessel NRC Quest.
The successful completion of NASA Commercial Resupply Mission 18 (CRS-18) means that SpaceX is officially the first and only company to launch the same orbital spacecraft three times. Meanwhile, Cargo Dragon capsule C108 also happened to mark the first known orbital flight test of hardware that may be destined for use on SpaceX’s next-generation Starship launch vehicle, taking the shape of four ceramic tiles installed as part of its ablative PICA-X heat shield.
Cargo Dragon’s CRS-18 mission successfully lifted off on its way to the International Space Station (ISS) on July 25th and was berthed to the ISS roughly two days later, completed its delivery of several tons worth of cargo. During the launch webcast, one of the SpaceX hosts noted that black tiles visible on Cargo Dragon’s heat shield – distinct beside its silvery water-sealed PICA-X tiles – were prototypes of a ceramic heat shield material being analyzed for possible use on Starship.
CEO Elon Musk confirmed this after the first launch attempt was scrubbed by weather, stating that SpaceX was looking into the use of “thin [ceramic] tiles” to protect Starship’s windward (atmosphere-facing) half during orbital reentries. Prior to this development, Musk had proposed and posted videos of real-world tests of a steel Starship heat shield concept, in which extra energy could be wicked away by ‘transpiring’ liquid oxygen or methane through microscopic holes on each tile’s leading edge.
Although particular species of stainless steel do feature exceptionally high melting points and structural characteristics at ultra-high temperatures (> 1400C/2500F), some unofficial analyses of the numbers involved indicated that the density and weight of steel could rapidly hinder any benefits derived from its use as a heat shield. Musk appeared to confirm this in his July 24th comments, indicating that thin ceramic tiles on the windward side and nothing on the leeward side of Starship looked like the “lightest option”.
Indeed, ceramics were so prevalent on the Space Shuttle – the only semi-routinely reusable space plane ever developed – in large part because they can be made spectacularly light. The Shuttle’s main ceramic tiles had a density of 155 kg/m³ (9 lb/ft³), about five times denser than styrofoam or roughly the same density as freshly-fallen snow and balsa wood. Stainless steel is about 50 times denser, on average. To use Musk’s own 2017 turn-of-phrase, adding thick steel tiles to Starship’s already-steel skin was probably a bit too much like “building a box in a box”, whereas prioritizing ceramic tiles presumably cuts the shield’s mass by a factor of something like 20-100+.
Although the Shuttle did make extensive use of ceramic shielding, that shielding – specifically, reinforced carbon-carbon (RCC) tiles about as fragile as the material people are familiar with – and a mixture of organizational ineptitude infamously lead to the death 7 NASA astronauts and was generally a nightmare to deal with. SpaceX certainly won’t have to deal with the foam and solid rocket boosters that a lot of Shuttle’s ceramic problems can be traced to, but the company will likely be laser-focused on producing a form of ceramic shielding that isn’t nearly as fragile as Shuttle-derived materials.
The fact that Cargo Dragon’s ceramic Starship tile prototypes appear to be almost completely unscathed after their first orbital reentry is an excellent sign that SpaceX is making progress in the materials design and certification department, or is at least taking flight-testing extremely seriously.
SpaceX CEO Elon Musk is expected to provide an official update on Starship no earlier than late September, a presentation that will likely include details about the route the company is taking with the massive spaceship’s heat shielding.
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Tesla supplier Samsung preps for AI5 production with latest move
According to a new report from Sedaily, Samsung is accelerating its preparation for U.S. production of the AI5 chips by hiring veteran engineers for its Customer Engineering team.
Tesla supplier Samsung is preparing to manufacture the AI5 chip, which will launch the company’s self-driving efforts even further, with its latest move.
According to a new report from Sedaily, Samsung is accelerating its preparation for U.S. production of the AI5 chips by hiring veteran engineers for its Customer Engineering team, which will help resolve complex foundry challenges, stabilize production and yields, and ensure manufacturing goes smoothly for the new project.
The hiring push signals that Tesla’s AI5 project is moving forward quickly at Samsung, which was one of two suppliers to win a contract order from the world’s leading EV maker.
🚨🚨 FIRST LOOK at Tesla’s AI5 chip, which will be available in late 2026 or early 2027 pic.twitter.com/aLomUuifhT
— TESLARATI (@Teslarati) November 6, 2025
TSMC is the other. TSMC is using its 3nm process, reportedly, while Samsung will do a 2nm as a litmus test for the process.
The different versions are due to the fact that “they translate designs to physical form differently,” CEO Elon Musk said recently. The goal is for the two to operate identically, obviously, which is a challenge.
Some might remember Apple’s A9 “Chipgate” saga, which found that the chips differed in performance because of different manufacturers.
The AI5 chip is Tesla’s next-generation hardware chip for its self-driving program, but it will also contribute to the Optimus program and other AI-driven features in both vehicles and other projects. Currently, Tesla utilizes AI4, formerly known as HW4 or Hardware 4, in its vehicles.
Tesla teases new AI5 chip that will revolutionize self-driving
AI5 is specialized for use by Tesla as it will work in conjunction with the company’s Neural Networks, focusing on real-time inference to make safe and logical decisions during operation.
Musk said it was an “amazing design” and an “immense jump” from Tesla’s current AI4 chip. It will be roughly 40 times faster, and have 8 times the raw compute, with 9 times the memory capacity. It is also expected to be three times as efficient per watt as AI4.
“We’re going to focus TSMC and Samsung, initially, on AI5. The AI5 chip, design by Tesla, it’s an amazing design. I’ve spent almost every weekend for the last few months with the chip team working on AI5.”
It will be 40x better than the AI4 chip, Musk says.
— TESLARATI (@Teslarati) October 22, 2025
AI5 will make its way into “maybe a small number of units” next year, Musk confirmed. However, it will not make its way to high-volume production until 2027. AI5 is not the last step, either, as Musk has already confirmed AI6 would likely enter production in mid-2028.
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Tesla discloses interesting collaboration partner for Supercharging
This BOXABL collaboration would be a great way to add a rest stop to a rural Supercharging location, and could lead to more of these chargers across the U.S.
Tesla disclosed an interesting collaboration partner in an SEC filing, which looks like an indication of a potential project at Supercharger sites.
Tesla said on Tuesday in the filing that it was entering an agreement with BOXABL to design and build a Micromenity structure. Simply put, this is a modular building, usually a few hundred square feet in size, and it has been seen at Superchargers in Europe.
In Magnant, France, Tesla opened a small building at a Supercharger that is available to all EV owners. There are snacks and drinks inside, including ice cream, coffee, a gaming console, and restrooms. It gives people an opportunity to get up and out of their cars while charging.
This building was not built by BOXABL, but instead by bk World Lounges. It is likely the final Supercharging stop before people get to Paris, as it is located 250 kilometers, or 155 miles, from the City of Light.
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Magnant has 56 stalls, so it is a large Supercharging stop compared to most. The building could be a sign of things to come, especially as Tesla has opened up larger Supercharger stations along major roadways.
It is for just a single building, as the Scope of Work within the filing states “a comprehensive package for one Micromenity building.”
NEWS: BOXABL, a company that creates modular, prefabricated buildings, has entered into an agreement with @Tesla.
This is Tesla formally contracting BOXABL to design, engineer, and build a pilot “Micromenity” structure, a compact, modular building unit.
While some info in the… pic.twitter.com/RabJczGpEp
— Sawyer Merritt (@SawyerMerritt) December 9, 2025
Superchargers are commonly located at gas stations, shopping centers, and other major points of interest. However, there are some stops that are isolated from retail or entertainment.
This BOXABL collaboration would be a great way to add a rest stop to a rural Supercharging location, and could lead to more of these chargers across the U.S.
Tesla has done a lot of really great things for Supercharging this year.
Along with widespread expansion, the company launched the “Charging Passport” this week, opened the largest Supercharger in the world in Lost Hills, California, with 168 chargers, opened the Tesla Diner, a drive-in movie restaurant in Los Angeles, and initiated access to the infrastructure to even more automakers.
Elon Musk
Tesla CEO Elon Musk confirms Robotaxi safety monitor removal in Austin: here’s when
Musk has made the claim about removing Safety Monitors from Tesla Robotaxi vehicles in Austin three times this year, once in September, once in October, and once in November.
Tesla CEO Elon Musk confirmed on Tuesday at the xAI Hackathon that the company would be removing Safety Monitors from Robotaxis in Austin in just three weeks.
This would meet Musk’s timeline from earlier this year, as he has said on several occasions that Tesla Robotaxis would have no supervision in Austin by the end of 2025.
On Tuesday, Musk said:
“Unsupervised is pretty much solved at this point. So there will be Tesla Robotaxis operating in Austin with no one in them. Not even anyone in the passenger seat in about three weeks.”
Musk has made the claim about removing Safety Monitors from Tesla Robotaxi vehicles in Austin three times this year, once in September, once in October, and once in November.
In September, he said:
“Should be no safety driver by end of year.”
The safety driver is just there for the first few months to be extra safe.
Should be no safety driver by end of year.
— Elon Musk (@elonmusk) September 4, 2025
On the Q3 Earnings Call in October, he said:
“We are expecting ot have no safety drivers in at least large parts of Austin by the end of this year.”
Finally, in November, he reiterated the timeline in a public statement at the Shareholder Meeting:
“I expect Robotaxis to operate without safety drivers in large parts of Austin this year.”
Currently, Tesla uses Safety Monitors in Austin in the passenger’s seat on local roads. They will sit in the driver’s seat for highway routes. In the Bay Area ride-hailing operation, there is always a Safety Monitor in the driver’s seat.
Three weeks would deliver on the end-of-year promise, cutting it close, beating it by just two days. However, it would be a tremendous leap forward in the Robotaxi program, and would shut the mouths of many skeptics who state the current iteration is no different than having an Uber.
Tesla has also expanded its Robotaxi fleet this year, but the company has not given exact figures. Once it expands its fleet, even more progress will be made in Tesla’s self-driving efforts.
Tesla supplier Samsung preps for AI5 production with latest move
Tesla discloses interesting collaboration partner for Supercharging
