SpaceX
There are many challenges involved in a mission to Mars. What are they and what technology is SpaceX working on to address them?
The concept of sending humans to Mars has been an exciting idea for decades, and the direction of space travel in the 21st century is finally presenting the possibility of actually making that happen. Of course, once everyone let the seriousness of such a journey sink in, the question of feasibility has inevitably come to the table for open discussion with the goal of finding realistic solutions.
It’s interesting enough to simply review the missions of all the Mars hopefuls (Part 1), but now that the reviews are in, it’s the details that are driving the discussion. After all, even the casual observer knows that deep space travel presents challenges such as long-term zero gravity and the ever-popular doom-and-gloom danger of cosmic radiation.
[Say that last one in a loud, booming voice for extra effect.]
Before breaking down any specifics, I want to acknowledge that there’s more than just a twelve-step program to getting to Mars (twelve being the obligatory “go-to” number). It requires an entire infrastructure of capabilities that build upon and support one another. However, I’m taking a leap of faith by assuming that inevitably anyone making a successful trip to Mars will have partnerships in place to tap into such an infrastructure. It’s the larger components of the specific missions that I’m focusing on here.
Outlining the Challenges for a Mission to Mars
NASA has a dedicated “Space Technology Mission Directorate” (STMD) charged with developing the capabilities needed to achieve the missions and goals NASA is given.
With the red planet as one of the big missions of the day (meaning Mars obviously, although Pluto has also been determined to be red), there’s no shortage of PowerPoints, panels, and interviews to source for what’s being worked on. I’ll follow their lead for discussion.
Transportation
First and foremost, in order to explore Mars, we’ve got to get there and (arguably) back. Depending on the length of stay and mission purpose, the cargo needs are going to play a part in the “how” part of this puzzle piece. Small stuff, no sweat (relative to general space traveler sweat levels). Big stuff? Now we’ve got issues.
Propulsion
Propulsion has been an interesting discussion to watch from the sidelines, mainly due to the debate over the types of systems available versus the types of systems thought to be needed. General mission discussions tend towards a six to eight month flight time each way plus a year and a half or so on the surface, but there are those advocating for shorter flight times to mitigate hazard exposure and reduce cargo needs.
Current rocket fuels can speed things along, but only at the expense of high fuel consumption. Nuclear fusion (and fission) systems are in the works which would theoretically reduce the flight time to Mars to approximately three months, but the timeframe needed to fully develop and test such new technologies isn’t a big crowd pleaser.
The methane-based nature of SpaceX’s Raptor engine for their speculated Mars Colonial Transport doesn’t really lend either way to this debate because using methane is a choice surrounding resource availability rather than power levels. Since methane can be harvested and manufactured on Mars, it reduces the need to carry as much fuel from Earth on missions, thus lowering costs. Methane-based fuel generation is also one of the key parts of the Mars Society’s “Mars Direct” proposal.
Entry, Descent, and Landing
Given the fact that we’ve sent several rovers to Mars already, it might be surprising that getting a craft from orbit to the Martian surface is actually a huge challenge. A quick survey of our recent history certainly makes the case for landing to be a non-issue, so what’s the deal?
Yes, we land heavy things on Earth all the time, but we do so with an atmosphere about 99% thicker than the one on Mars. The lack of air pressure and wind on Mars means that there isn’t any real air resistance to aid in slowing down a massive descending craft nor is there any wind to tap into for a glider or parachute to be very effective.
What about the moon?
There’s virtually no atmosphere there, either, yet we landed quite a bit of cargo during the Apollo program. That explanation would be gravity. The moon has less than half the gravity that Mars does, which is less than 20% that of Earth. The difference in power required to land a crew module on the moon vs. Mars could maybe be compared to landing a mini Falcon 9 with a micro drone onto a piece of plywood in the middle of a swimming pool versus dropping, say, a child-sized Tesla Model S. Maybe not, but it’s fun to think about. So cute…
In 2012, NASA landed the rover “Curiosity” on the Martian surface using a very complicated parachute-plus-propulsion crane system. The existence of such technology somewhat gives the impression that landing things on Mars is already a solved problem. If what we’re landing is about the mass of a small car, this impression is true, but if we are landing anything significantly larger, such as a capsule carrying humans for example, then the problem is still a problem as larger masses require greater counterforce to slow down their descent.
SpaceX Gives Back
SpaceX’s focus on developing propulsive landing systems is aiming to solve the problem of counterforce. This is actually an area where SpaceX is supporting NASA’s Journey to Mars (instead of the other way around) via the data obtained from their Falcon 9 landings to date. One of NASA’s proposed solutions is a “supersonic retropropulsion” system, meaning periodic firing of the engines on a craft to counter the speed resulting from a trip through the (small) Martian atmosphere. To date, NASA hasn’t been able to test this type of technology in an environment similar to what would be encountered on Mars whereas SpaceX has. By studying the results of SpaceX’s Falcon 9 first stage landings, NASA can use the information gathered for their retropropulsive system designs.
Back scratchers, unite!
Crew Systems
The crew ships under development for taking astronauts to Mars have a number of requirements to meet to be successful transports, and from the information available thus far, their progress seems to be moving along swimmingly. SpaceX’s Crew Dragon has been announced with photos and basic details provided, and NASA’s Orion capsule has enjoyed a marketing campaign providing numerous details for quite some time now.
The primary improvements in both capsule designs over the Apollo age seem to be more room, better heat shields, better software, and glass cockpits (i.e., touch screens). Crew Dragon can also hover (eventually landing) and blast off from its rocket transport in an emergency event. The aesthetics are pretty swank as well. Why isn’t there anything vastly different from what we’ve already done?
If it ain’t broke, don’t fix it.
Crew Cargo & Environmental Systems
Environmental systems and supplies to keep human travelers alive and (mostly) happy have been generally worked out via prior orbital missions, especially on the long-term International Space Station (ISS) ones. However, there are a few added “catches” that a mission to Mars throws in.
First, the ISS is able to maintain long-term human crews due to regular cargo resupply missions. The travel distance for Mars-bound astronauts will render such types of delivery schedules unavailable. No cargo deliveries mean carrying all the cargo required for the entire trip, something that generally demands multiple rocket launches for supply assembly before heading out.
Other than the higher expense of multiple launches, this seems to just be a matter of logistics and cost effectiveness rather than capability. SpaceX’s Falcon Heavy was certainly designed with these cargo requirements in mind considering the power packed into its engines.
Second, life support system technology has been developed and advanced over the years on the ISS, but it requires a lot of maintenance to upkeep. Perhaps the life support systems on the new crew capsules will endure for longer than the systems on the ISS as they have the data available to design around, but in the event that upkeep is just a fact of life that can’t be prevented, crews will surely undergo the training to perform repairs as needed as they are now.
As development in the space industry continues, these issues may become minimal. For instance, short-term resupply missions could eventually become available as travel time to Mars decreases with more efficient and powerful propulsion systems. The development of photon propulsion via lasers is ongoing, the goal being to accelerate around 220 pounds of unmanned spacecraft to 25% the speed of light for a three-day trip to Mars. That could almost translate into a sort of Mars-based Amazon Prime. I see what you’re up to, Jeff Bezos!
SpaceX also plans on making regular cargo missions to Mars a bi-annual affair, so as long as supplies and equipment can last for the 26-month(ish) window between launches, it’s Mars-certified.
Zero Gravity Impacts
When astronauts return from long-term zero gravity, their bodies have to acclimate after changes despite attempts to mitigate the effects through exercise regimens. If you’re just going from Earth to space and then Earth again, no big deal really. But going from Earth to space and then Mars? There won’t be a team of medical professionals ready to drag the astronauts out of the capsule and tell them to take it easy for a while.
That’s kind of an amusing image, actually. The Red Dragon capsule lands but everyone inside is all laid out looking like they are badly hungover from the prior night’s club hopping. Throw in some glitter for Instagram? Sorry, I’m digressing…
What exactly are the effects of long-term zero gravity on the human body? According to NASA, muscles (including the heart) can atrophy at a rate of 5% per week, bones at 1% per month, and about 22% of blood volume is lost. These are generally recoverable, but it takes about as long to recover a muscle as it did to lose it, and bone can take two to three years to grow back if it does at all. The lower Mars gravity would probably mean an easier recovery process, but there’s still a process involved and the entire crew is affected. Not even regular exercise can mimic all of the (needed) effects that gravity has on the body.
The concept of using a rotating space craft to mitigate this problem is seen so often in movies and space habitat designs that one might think it’s a “given” that some version of it will be used for Mars travel. In fact, The Mars Society’s “Mars Direct” plan even advocates for a rotating craft which uses the spent upper stage of the rocket as an anchor to spin the crew capsule around for artificial gravity simulation.
Since nothing looked like it would “spin” on the Dragon and Falcon Heavy media releases nor did there seem to be much room for a treadmill, I was really curious about what SpaceX’s answer to long term zero gravity was. From what I’ve read, it isn’t seen as a real problem or “show stopper”, if you will. Again, I’m missing a direct source to cite for any Elon or SpaceX comment on the issue, but from commentary around the web, it seems that the issue has surfaced in public discussions with no particular technology addressed to overcome it.
Perhaps this is one more thing we will see come September when SpaceX’s Mars Colonial Transporter plans are revealed. I can’t imagine that one hundred body-worn, space-traveling colonists wouldn’t be a problem needing to be addressed.
Surface Power
When it comes to any sort of space travel, solar seems to be one of the “go to” choices for power sourcing outside of propulsion. Unfortunately, when it comes to Mars exploration, solar power alone may not be enough. For one thing, Mars receives less than half the sunlight that Earth does, and most of that sunlight is only available in certain regions of the planet such as around the equator. Frequent light-blocking dust storms are also a problem. NASA’s STMD has outlined advanced batteries, regenerative fuel cells, fission nuclear systems, and solar arrays as the choice technologies for development in the area of surface power.
Now, I admit that I don’t have all the time in the world to watch every Elon Musk video in existence (although I do enjoy the convenience of a YouTube channel with nearly all of them compiled), but I haven’t had much luck finding original sources of either Elon or a SpaceX executive directly commenting on the subject of surface power. I’m sure something is out there either eluding me or that I’ve forgotten I’ve seen.
Crew Dragon uses solar arrays attached to its trunk during flight for power, but the trunk is jettisoned prior to reentry (or entry when talking about Mars). I could make an educated guess based on the connections between Elon Musk and Solar City, Tesla, and the methane-based Raptor engines to presuppose that solar power, advanced batteries, and methane fuel generation are part of SpaceX’s surface power plans, but in the end it’s just a guess. Also, if Raptor is using a methane-based fuel because it can be resourced outside of Earth, I’d imagine that surface power would tie into that same manufacturing capability.
Mars One plans to utilize solar power for its surface power needs, specifically “thin film solar photovoltaic panels”. There isn’t much detail about their required panel size available, only that they should have the ability to be rolled up and transported elsewhere if need be. Finally, as I mentioned previously, the “Mars Direct” plan advocates tapping into fuel generation structures that manufactures a Methane-Oxygen bi-propellant.
Overall, it seems everyone is likely on a similar page regarding power sources – nothing crazy or unheard of, unless you think nuclear anything is too risky.
Coming Up on Countdown to Mars…

Wernher von Braun and Walt Disney | Credit: NASA on The Commons
Cosmic space radiation! There’s so much on this topic, it’s worth an entire piece on its own. Spoiler alert: Elon doesn’t seem to be worried about that issue. Why not?
Also, stay tuned for a (theoretical) discussion on future Martian government…
Did you know that Werner von Braun had a fictional tale of a Martian society wherein the elected Martian leader was called “The Elon”? It’s almost as though he really did take a trip on that Nazi time traveling bell thing…
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.










