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SpaceX awarded three more NASA astronaut launch contracts

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Three months after announcing its intent, NASA has procured three more Crew Dragon astronaut launches from SpaceX, raising the total number of operational missions the company is contracted to perform from six to nine.

NASA announced its plans to award additional contracts in December 2021 after releasing a half-hearted Request For Information (RFI) in October. That RFI, which seemingly lacked any real NASA support for an attempt to develop one or more additional crew transport vehicles, unsurprisingly produced the conclusion that the space agency should buy more flights from its existing providers.

Short of a second Commercial Crew Program (CCP), Boeing and SpaceX were thus the only options. Boeing, whose Starliner spacecraft has yet to successfully complete even an uncrewed test flight and remains years behind schedule, was apparently ruled out of this contract add-on. SpaceX, on the other hand, aced uncrewed and crewed Crew Dragon test flights in March 2019 and May 2020 and ultimately began operational astronaut transport missions in November 2020, making it the only logical option.

As such, NASA announced that it would award three more transport contracts to SpaceX, raising the total value of its Commercial Crew Transportation Capability (CCtCap) contract from about $2.6 billion to $3.49B. As of August 2019, NASA’s Office of the Inspector General (OIG) reported that of the original $2.6 billion SpaceX was awarded, the company planned to spend $1.2 billion on development and test flights and $1.4 billion on up to six operational Crew Dragon missions.

Crew Dragon aced its first uncrewed demo flight (DM-1) in March 2019. (NASA)
Demo-2 – Dragon’s first crewed test flight – was just as successful from May to August 2020. (NASA)

At the time, that meant that NASA intended to pay a total of ~$230 million for each of the first six Crew Dragon transport missions, each of which would carry four astronauts to and from the International Space Station and serve as a lifeboat in the six months between launch and landing. For NASA’s contract modification, the space agency will now pay the company no more than $890 million – up to $297 million apiece – for three more transport missions, each likely carrying four astronauts.

For missions seven through nine, NASA will thus pay an average of up to ~$74 million per seat – substantially more expensive than the ~$55 million per seat SpaceX’s first six Crew Dragon missions will cost the space agency. To be clear, there’s a chance that a significant fraction of the $890 million contract value increase actually came before the addition of three more missions, in which case NASA might instead be paying around $700-800 million or around $60-70M per seat for three more Dragon launches. Regardless, that’s cheaper than the ~$90 million per seat Boeing’s Starliner is expected to cost. At the end of NASA’s Soyuz ridesharing efforts, the agency was also being gouged for about ~$90 million per seat to launch its astronauts on Russian Soyuz missions.

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Update: There is evidence that SpaceX’s total CCtCap contract value was about $2.74 billion before the addition of three more missions, meaning that NASA is likely paying SpaceX around $755 million or ~$63 million per seat – a more reasonable 15% increase over earlier pricing.

Starliner has only flown once and was nearly lost twice on its first December 2019 test flight. (NASA/Bill Ingalls)
SpaceX recently launched Crew Dragon’s third successful NASA astronaut transport mission in November 2021. (NASA)

SpaceX remains on track to launch Crew-4 no earlier than (NET) 15 April 2022, Crew-5 NET October 2022, and Crew-6 NET February 2023. The company is now expected to complete all six of its first operational crew transport missions before Boeing’s Starliner spacecraft completes a single one. In fact, it’s increasingly plausible that SpaceX will launch all six of its original Crew missions before Starliner attempts its first crewed test flight – a milestone Crew Dragon passed in May 2020.

It remains to be seen when Starliner will finally become operational. If Boeing manages that feat by mid-2023, there’s at least a chance that Starliner and Crew Dragon will finally be able to start alternating launches, in which case NASA’s three extra Dragon launches might last until 2027. Starliner would then have three more missions remaining, allowing NASA to stretch its 15 existing Commercial Crew transport contracts as far as H2 2028.

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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GM takes latest step to avoid disaster as EV efforts get derailed

There was an even larger step taken this morning, as the Detroit Free Press reported that GM was idling its Factory Zero plant in Michigan until late November, placing about 1,200 workers on indefinite layoff status.

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Credit: GM

General Motors has taken its latest step to avoid financial disaster as its electric vehicle efforts have been widely derailed.

GM’s electric vehicle manufacturing efforts started off hot, and CEO Mary Barra seemed to have a real hold on how the industry and consumers were starting to evolve toward sustainable powertrains. Even former President Joe Biden commended her as being a major force in the global transition to EVs.

However, the company’s plans have not gone as they’ve drawn them up. GM has reported some underwhelming delivery figures in recent quarters, and with the loss of the $7,500 tax credit, the company is planning for what is likely a substantial setback in its entire EV division.

Earlier this month, the company reported it would include a $1.6 billion charge in its quarterly earnings results from EV investments. It was the first true sign that things with GM’s EV projects were going to slow down.

There was an even larger step taken this morning, as the Detroit Free Press reported that GM was idling its Factory Zero plant in Michigan until late November, placing about 1,200 workers on indefinite layoff status.

This is in addition to the 280 employees it has already laid off after production cuts that happened earlier this year at the Detroit-Hamtramck plant.

After November 24, GM will bring back 3,200 people to work until January 5 to operate both shifts. On January 5, GM is expected to keep 1,200 workers on indefinite layoff.

GM is not the only legacy automaker to make a move like this, as Ford has also started to make a move that reflects a cautious tone regarding how far and how committed it can be to its EV efforts.

After the tax credit was lost, it seemed to be a game of who would be able to float their efforts longest without the government’s help. Tesla CEO Elon Musk long said that the loss of these subsidies would help the company and hurt its competitors, and so far, that is what we are seeing.

Elon Musk was right all along about Tesla’s rivals and EV subsidies

However, Tesla still has some things to figure out, including how its delivery numbers will be without the tax credit. Its best quarter came in Q3 as the credit was expiring, but Tesla did roll out some more affordable models after the turn of the quarter.

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Tesla expands Robotaxi geofence, but not the garage

This has broadened its geofence to nearly three times the size of Waymo’s current service area, which is great from a comparative standpoint. However, there seems to be something that also needs to be expanded as the geofence gets larger: the size of the Robotaxi fleet.

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Credit: Joe Tegtmeyer | X

Tesla has expanded its Robotaxi geofence four times, once as recently as this week.

However, the company has seemingly kept its fleet size relatively small compared to the size of the service area, making some people — even pro-Tesla influencers — ask for more transparency and an expansion of the number of vehicles it has operating.

Over the past four months, Tesla has done an excellent job of maintaining growth with its service area in Austin as it continues to roll out the early stages of what is the Robotaxi platform.

The most recent expansion brought its size from 170 square miles (440.298 sq. km) to 243 square miles (629.367 sq. km).

Tesla sends clear message to Waymo with latest Austin Robotaxi move

This has broadened its geofence to nearly three times the size of Waymo’s current service area, which is great from a comparative standpoint. However, there seems to be something that also needs to be expanded as the geofence gets larger: the size of the Robotaxi fleet.

Tesla has never revealed exactly how many Model Y vehicles it is using in Austin for its partially driverless ride-hailing service (We say partial because the Safety Monitor moves to the driver’s seat for freeway routes).

When it first launched Robotaxi, Tesla said it would be a small fleet size, between 10 and 20 vehicles. In late August, after its second expansion of the service area, it then said it “also increased the number of cars available by 50 percent.”

Tesla reveals it has expanded its Robotaxi fleet in Austin

The problem is, nobody knows how many cars were in the fleet to begin with, so there’s no real concrete figure on how many Robotaxis were available.

This has caused some frustration for users, who have talked about the inability to get rides smoothly. As the geofence has gotten larger, there has only been one mentioned increase in the fleet.

Tesla did not reveal any new figures or expansion plans in terms of fleet size in the recent Q3 Earnings Call, but there is still a true frustration among many because the company will not reveal an exact figure.

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Tesla recalls 6,197 Cybertrucks for light bar adhesive issue

On October 20, Tesla issued a voluntary recall of the impacted vehicles and has identified 619 warranty claims and just a single field report that is related to the issue. 

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Credit: Francisco Garcia (via Greggertruck on X)

Tesla has recalled 6,197 Cybertrucks for a light bar adhesive issue that was utilized by Service to install the aftermarket part.

According to the National Highway Traffic Safety Administration (NHTSA), impacted vehicles may have had the light bar “inadvertently attached to the windshield using the incorrect surface primer.”

Tesla identified an issue with the light bar’s adhesion to glass back in February and worked for months to find a solution. In October, the company performed chemical testing as a part of an engineering study and determined the root cause as the BetaPrime primer it utilized, figuring out that it was not the right surface priming material to use for this specific application.

On October 20, Tesla issued a voluntary recall of the impacted vehicles and has identified 619 warranty claims and just a single field report that is related to the issue.

The component is manufactured by a Romanian company called Hella Romania S.R.L., but the issue is not the primer’s quality. Instead, it is simply the fact that it is not the correct adhesive for this specific type of application.

Tesla says there are no reports of injuries or deaths due to this issue, and it will be resolved. In the 473 report that the NHTSA released this morning, Tesla said:

“At no charge to customers, Tesla will inspect the service-installed optional off-road light bar accessory for delamination or damage and if either is present, replace the light bar with a new light bar adhered with tape and a positive mechanical attachment. If no delamination or damage is present, Tesla will retrofit the service-installed optional off-road light bar accessory with a positive mechanical attachment.”

This is the third recall applied to Cybertrucks this year, as one on March 18 highlighted the potential for exterior trim panels to detach while driving, and another earlier this month when the NHTSA said its front parking lights were too bright.

Tesla resolved the first with a free assembly replacement, while the headlight issue was fixed with an Over-the-Air software update earlier this week. Owners said there was a noticeable difference in the brightness of the lights now compared to previously.

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