SpaceX
What SpaceX’s successful reuse of Dragon Spacecraft really means
Following Saturday’s auspicious launch and and first stage recovery, SpaceX’s Dragon spacecraft has successfully rendezvoused and docked with the International Space Station. Bringing with it more than 5,000 pounds of food, water, scientific experiments, and technology demonstrations, the company’s eleventh mission under their first Commercial Resupply Services contract is exceptional for a very unique and specific reason: the vehicle has flown before, bringing cargo to the ISS on SpaceX’s fourth CRS mission to the ISS. This accomplishment makes the Dragon currently docked at the ISS the only commercial spacecraft in human history to be launched into orbit more than once, continuing a tradition of auspicious firsts.
CRS-11 just after liftoff. Note the core designation “35” under the landing leg. (SpaceX)
Slightly more than two months after the first ever successful reuse of an orbital-class rocket, SpaceX now has two extraordinary demonstrations of success in favor of the company’s pursuit of democratizing affordable access to space. Reusability is and has been SpaceX’s method of pursuing that goal for at least a decade, with Musk publicly exhorting the potential benefits of rapid and complete reusability as early as 2007. It is almost a running joke within the community of aerospace and SpaceX fans that Musk will compare commercial airlines to orbital launch services at least once every time he is interviewed, but his point is and has long been clear. If all one has to do to run a transportation service is refuel after every trip, the price of a ticket or cargo transport drastically decreases. While many have slyly laughed or dismissed this goal in the past, often using the Space Shuttle as an example of the futility of reusability as a tool for cost reduction, it is quite hard to deny what SpaceX has accomplished so far.
The reuse of a Cargo Dragon is also arguably far more significant than it may initially appear. SpaceX has not provided any concrete information on the process of refurbishing the capsule, and it is entirely unclear if the “reuse” entailed much more than furnishing the CRS-4 pressure vessel and Draco thrusters with a new trunk, solar array, external shell. It is possible that, just like SES-10, the process of refurbishing a spacecraft for the first time resulted in little to no cost savings, and that this refurbishment took anywhere from several months to more than a year, with the CRS-4 capsule returning from orbit in late 2014. However, given the absolute rarity of reused capsule-type spacecraft, the data that engineers likely gathered throughout the process of refurbishing the Dragon would arguably make the whole process worthwhile even in the worst case scenarios described above. Hans Koenigsmann, Vice President of Mission Assurance at SpaceX, also noted in a press conference following CRS-11’s launch that the refurbishment of the capsule was somewhat uneventful, stating that the CRS-4 capsule had no unanticipated damage from the rigors of reentry and ocean landing and that SpaceX was already ready to consider using the capsule a third time. It’s likely that SpaceX will begin to rely more heavily on Cargo Dragon reuse as they refocus a majority of their manufacturing efforts on Dragon 2.
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- The CRS-4 Dragon just before capture. (NASA)
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- CRS-4 reentered in late 2014 and was recovered in the Pacific Ocean. (SpaceX)
SpaceX and Musk’s (in)famous ultimate ambitions are to make humanity a multiplanterary species, partly as a way to combat the extinction risks that an asteroid or comet strike pose, and partly because it is simply a staggering challenge that has the potential to make many humans “excited to wake up in the morning”. In order to make this happen, Musk saw that access to orbit was far too expensive for a colony on another planet to ever be sustainable, and that resuability was the only immediately obvious and accessible method through which the price to orbit could be decreased by several magnitudes. SpaceX is now almost routinely recovering Falcon 9 first stages when the mass of the payload allows it, and with a fifth and final version or “Block” of the vehicle optimized for rapid reuse set to debut later this year, Musk and others at the company have begun ruminating once more about the possibility of recovering and reusing the second stage of the Falcon 9. Benchmarked somewhere around 30% of the price of the vehicle, routine loss of the second stage effectively prevents the price of the Falcon 9 from dropping much below $20-30 million US dollars. While a nearly 50% or greater reduction in price would be an exceptional accomplishment, it is still far from from the multiple orders of magnitude reduction Musk hoped for when he set out to develop reusable rocketry.
A prototype of Dragon 2 being tested in an anechoic chamber. (SpaceX)
This is where the reuse of Dragon pops its head up. With second stage recovery now being considered theoretically and Dragon 2 (Crew Dragon) preparing to begin regular launches in either Q4 2017 or Q1 2018, SpaceX has a good deal of experience to gain from learning how to safely and rapidly recover and reuse vehicles reentering the atmosphere at orbital velocity. Compared to recovering the first stage, this is another endeavor entirely. The fastest speed at which a recoverable first stage can ever realistically reenter the atmosphere is currently capped at around 5200 mph (2300 m/s), and is usually much closer to 3000 mph. An orbital capsule like Dragon, however, enters the atmosphere from Low Earth Orbit (LEO) at around five times that speed, typically close to 16,000 mph. In the context of recovering the second stage of Falcon 9, one must consider that most of SpaceX’s commercial manifest is made up of geostationary satellites, which require more energy to reach a higher orbit, and consequently would require the second stage to survive even higher reentry velocities in order to be recovered.
Returning from Mars, as SpaceX’s Interplanetary Transport System would have to, results in even higher reentry velocities of at least 25,000 mph for a reasonably quick journey. This is the most important detail in explaining the true value of simply reusing a Dragon capsule as SpaceX has just now done. By taking its first steps towards routinely reusing truly orbital spacecraft, SpaceX is advancing their knowledge reusability in practice and consequently taking concrete steps to prepare themselves for the difficult challenges that lie ahead in their pursuance of enabling sustainable colonization of Mars. Dragon 2 (Crew Dragon) promises to eventually rid the refurbishment process of the many headaches that salt water intrusion undoubtedly creates by returning via supersonic retropropulsion to a landing pad, much like Core 35 did this past Saturday.
Looking slightly further into the future, SpaceX has already announced plans to launch two unnamed private customers in a Dragon 2 on what would likely be a circumlunar free return trajectory, or around the Moon and back. The reentry velocity would be very similar to the velocity required to return to Earth from Mars, and certainly much faster than any reentry from geostationary orbits of Earth. If SpaceX manages to successfully and reliably recover and reuse orbital vehicles reentering at such high velocities, then the company will have made extraordinarily promising progress towards achieving their central goal of drastically lowering cost to orbit and thus enabling humanity to gain footholds on other planets.
So, take this Dragon reuse as you will. It may well be a major step along the way to colonizing Mars, or it may simply be an exciting practical implementation of SpaceX’s philosophy of reuse. Either way, this is a Dragon that is certainly worth celebrating.
News
NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded
NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.
NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.
SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.
We’re excited for Falcon 9 and Dragon to launch @NASA’s Crew-15, 16, and 17 missions to the @Space_Station from Florida https://t.co/Qm16vVK9F3 pic.twitter.com/drg3s7GtuM
— SpaceX (@SpaceX) September 18, 2026
The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.
Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.
Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.
Investor's Corner
New drone video shows Tesla’s Optimus Factory reaching a turning point
New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.
Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.
The Giga Texas Optimus Factory latest update … construction keeps moving fast!
Steel assembly is now only about 5 column grids from the north perimeter beam. Concrete is going in on the three upper floors, rebar is still being laid for more pours, and footing / grade-beam work… pic.twitter.com/qvFPvwnYzW
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) September 17, 2026
Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.
Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.
Tesla Giga Texas to feature massive Optimus V4 production line
The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.
Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.
Investor's Corner
Tesla and SpaceX take “Terafab” Trademark fight to Federal Court
Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.
Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.
The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.
What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.
Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry
By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.
TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.
Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.
The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.
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