Why the ‘Mother of Dragons’ at SpaceX left her job building rockets to work on nuclear fusion
Darby Dunn, the Vice President of operations at Commonwealth Fusion Systems.
Photo courtesy Commonwealth Fusion Systems
From March 2009 to December 2018, Darby Dunn held a handful of engineering and production roles at SpaceX.
“In one role in particular, my unofficial title was ‘Mother of Dragons,'” Dunn told CNBC in an interview in Devens, Massachusetts. “In that role, I was leading the build out of our new manufacturing facilities for the crew Dragon vehicle.”
While she was overseeing production of the Dragon spacecraft, SpaceX went from ramping up production to making its very first spacecraft, and then to sending cargo to the International Space Station on it regularly, Dunn says.
Building rockets is a very cool thing to do. But in January 2019, Dunn started work at Commonwealth Fusion Systems, a startup that is attempting to commercialize nuclear fusion as an energy source. Fusion is the way the sun and the stars make energy. If it can be harnessed here on Earth, it would provide virtually unlimited clean energy.
But so far, fusion at scale remains in the realm of science fiction.
Darby Dunn with the SpaceX Dragon rocket.
Photo courtesy Darby Dunn
Dunn says she made the switch from building rockets to working on making fusion energy a reality because she wants to see the impact of her efforts in her lifetime.
“I very much believe SpaceX will make life multiplanetary. I don’t know how much of that I’ll see in my lifetime,” Dunn, 37, told CNBC at the end of May.
But Dunn has spent large chunks of her life living in California, where SpaceX is based, and has very much seen the effects of climate change in the shape of wildfires and mudslides stemming from extreme rain.
“For me, it really came down to wanting to use my energy to clean up the planet instead of get off it. So that was the the huge shift for me to come to CFS,” Dunn told CNBC.
Joining Commonwealth Fusion Systems in the early stages, as its 10th employee, has allowed her to see a different stage on the journey of company growth, too.
“We’re a 5-year-old company with 500 employees,” Dunn told CNBC. “I joined SpaceX when it was 6 years old with about 500 employees. So I’ve actually been able to see the entire era that I didn’t get to experience at SpaceX and doing so at CFS.”
The Commonwealth Fusion Systems campus in Devens, Mass.
Photo courtesy Commonwealth Fusion Systems
A key difference between the two jobs is the maturity of the respective industries.
“The aerospace industry has been around for a long time. So building a rocket engine, the mechanics of it look really similar, or the structure itself, or the physics of how it works is all very, very well studied and very well understood,” Dunn told CNBC.
Fusion machines have been studied in academic settings and research labs since the early 1950s, but the entire industry is just at the very first stages of trying to prove that the science can have commercial applications. It’s being a part of that excitement that was a big draw for Dunn.
Of course, there are plenty of skeptics who say the industry is the equivalent of Don Quixote tilting at his windmills. But Dunn says her time at SpaceX prepared her to face the skeptics.
“When Elon said publicly that we were going to launch and land rockets back from space, everybody said, ‘That’s not possible! You can’t do it!'” Dunn said, referencing SpaceX CEO Elon Musk. SpaceX’s response was that the laws of physics say it is possible and so they were going to prove it, Dunn told CNBC.
“It took many attempts, a lot of learning, a lot of iterations on our software, many failed attempts off the boat — and then we did it. And then we did it again. And we did it again. And we did it again,” she said.
Darby Dunn, vice president of operations at Commonwealth Fusion Systems.
Photo courtesy Commonwealth Fusion Systems
“Now it’s gotten to the point where you’ve seen the aerospace industry shift to say, ‘Well, why aren’t these other companies also lending their rockets back from space?’ It’s completely changed the way that people are looking at it. They first said, ‘It wasn’t possible. Then, ‘OK, it is possible.’ And now it is saying, ‘Well, why isn’t everybody else jumping in?'”
Dunn is looking to be part of that kind of transition for the fusion industry at Commonwealth.
Speed is key
Dunn is the vice president of operations, which covers manufacturing, safety, quality and facilities. She’s helping Commonwealth make the transition from research and development-scale processes to manufacturing and full-scale production.
The company spun out of research at Massachusetts Institute of Technology and the company’s goal is to build 10,000 fusion power plants around the world by 2050, Dunn told CNBC.
First, however, Commonwealth has to prove that it can generate more energy in its fusion reactor than is necessary to get the reaction started, a key threshold for the fusion industry called “ignition.” To do that, the company is currently building its SPARC tokamak — a device that will help contain and control the fusion reaction. The company plans to turn it on in 2025 and demonstrate net energy shortly thereafter.
To build SPARC, Commonwealth needs to make a lot of magnets using high-temperature superconducting tape.
The advanced manufacturing facility located at the Commonwealth Fusion Systems campus in Devens, Massachusetts, where magnets are manufactured.
Photo courtesy Commonwealth Fusion Systems
“The cool part of this building is that the concept for it started out as a doodle that I made on a whiteboard three years ago,” Dunn told CNBC. “To see the steel beams going up, walls going up, concrete getting poured, it’s a whole vision coming to life, which is super exciting.”
To fund the construction, Commonwealth has raised more than $2 billion from investors including Bill Gates, Google, Khosla Ventures and Lowercarbon Capital.
Even as Commonwealth is figuring out how to make one magnet, Dunn is leading her team to develop manufacturing processes that can eventually scale to a process that looks like an automotive assembly line, she told CNBC.
Moving fast is a priority for Dunn, and the rest of the team. After building the demonstration fusion machine, SPARC, the company aims to build a bigger version called ARC, which it says is going to deliver electricity to the grid. The aim is to have ARC online in the 2030s.
“The biggest thing I think about a lot is time, about how fast can we go,” Dunn told CNBC. “The sooner we can get the magnets built, the sooner we can build SPARC, the sooner we can turn it on, the sooner we can get in net energy, the sooner we get to our first ARC. So I think that’s probably the element that I think about the most.”
Darby Dunn in the Commonwealth Fusion Systems advanced manufacturing facility.
Photo courtesy Commonwealth Fusion Systems
Speed matters because critics argue that it will take too long to get fusion to work as an energy source to meaningfully contribute to the very urgent need to reduce greenhouse gas emissions.
Top climate scientists at the United Nations Intergovernmental Panel on Climate Change have said that to have “no or limited” overshoot of the 1.5 degrees Celsius warming above preindustrial levels will require a 45% reduction in carbon dioxide emissions by 2030 compared to 2010 levels and hitting net zero around 2050.
“I have asked myself, ‘Why am I doing fusion as opposed to something that is going to be deployed next year?'” she told CNBC. “For me, it comes down to the fact that fusion is the most energy dense reaction in our solar system.”
But she does not believe fusion should be the only solution.
“I very much believe in in solar power and wind and a lot of other renewables — that we absolutely need those. We need those deployed now. We need those deployed all over the world,” Dunn told CNBC. “But I don’t think they will be enough to get us to 2050 and beyond.”
Electric cars, heat pumps, green steel and green cement all depend on having large quantities of clean electricity. Its Dunn’s focus to build the energy sources that the world will need in the decades and centuries to come.
If Commonwealth is going to deliver that solution, though, Dunn first has to make a whole lot of very high-powered magnets.
“My own personal opinion is I’m going to keep on keeping on — keep on building. And we have a poster in the back stairwell that says, ‘Keep calm and fuse on,” Dunn told CNBC. “Regardless of what the outside world is saying, we are working every day towards our mission of getting net-positive energy from fusion. And I look forward to proving that to the world in a couple of years.”
Technology
UnitedHealth is making struggling doctors repay loans issued after last year’s cyberattack
UnitedHealth CEO Andrew Witty testifies before the Senate Finance Committee on Capitol Hill in Washington, May 1, 2024.
Kent Nishimura | Getty Images
Following the massive cyberattack on UnitedHealth Group’s Change Healthcare unit last year, the company launched a temporary funding assistance program to help medical practices with their short-term cash flow needs, offering no-interest loans with no added fees.
A little over a year later, UnitedHealth is aggressively going after borrowers, demanding they “immediately repay” their outstanding balances, according to documents viewed by CNBC and providers who received funding. Some groups have been asked to repay hundreds of thousands of dollars in a matter of days.
Optum, UnitedHealth’s financial, pharmacy and care services arm, is telling borrowers that it reserves the right to “begin offsetting claims payable” to the practices, meaning the company will withhold separate funds until it recoups the loan.
It’s a significant change in posture for the company, which suffered a cyberattack in February 2024 that compromised data from around 190 million Americans, the largest reported health-care breach in U.S. history. The ensuing disruption caused severe fallout across the health-care system, leaving many providers temporarily unable to get paid for their services. Some dipped into their personal savings to keep their practices afloat.
During a Senate hearing about the attack in May, UnitedHealth CEO Andrew Witty said providers would only be required to repay the loans when “they, not me, but they confirm that their cash flow is normalized.”
Several doctors who took advantage of the financing told CNBC that they can’t meet the company’s new demands. Dr. Christine Meyer, an internist who started a practice in Exton, Pennsylvania, received a letter from Optum earlier this month telling her to immediately submit her organization’s payment.
“We are not in any position to start repaying this loan,” Meyer, who started her practice about 20 years ago, told CNBC. She has been a vocal critic of UnitedHealth following the breach.
“I’m just looking at all my legal options at this point,” Meyer said. “But repaying them $750,000 in five days is obviously not going to happen.”
UnitedHealth didn’t comment on specific cases, but a spokesperson for Change Healthcare confirmed that the company has started recouping the loans.
“Now, more than one year post the event and with services restored, we have begun the process of recouping the interest-free funding we provided to providers,” the spokesperson said in a statement.
The company said the U.S. Department of Health and Human Services took the same approach last year “under its own cyber-attack lending program.” HHS launched a separate funding assistance program through the Centers for Medicare & Medicaid Services last March. CMS said it would automatically recoup payments from Medicare claims, and providers could accrue interest, according to a release.
“We continue to work with providers on repayment and other options, and continue to reach out to those providers that have not been responsive to previous calls or email requests for more information,” the Change Healthcare spokesperson said.
Providers were told that UnitedHealth reserved the right to withhold future payments when they signed up for the funding assistance program, the company added. CNBC independently reviewed a copy of a loan agreement for the program and confirmed this statement.
Change Healthcare, which offers payment and revenue cycle management tools, was acquired by Optum in 2022.
After discovering the breach last year, UnitedHealth said it isolated and disconnected the impacted systems. The company paid out more than $9 billion to providers in 2024, and more than $4.5 billion has already been repaid, according to the company’s fourth-quarter earnings report in January. UnitedHealth said providers would receive an invoice once standard payment operations resumed, and that they would be subject to a repayment period of 45 business days.
“Change Healthcare will notify the recipient that the funding amount is due after claims processing or payment processing services have resumed and payments impacted during the service disruption period are processed,” the website says.
Dwindling deposits, lost revenue
While the vast majority of Change Healthcare’s services have been restored over the course of the last year, three products are still listed as “partial service available,” according to UnitedHealth’s cyberattack response website.
And doctors are still reeling.
Meyer said that when the breach took place, she watched her practice’s daily deposits shrivel from the range of $60,000 to $80,000 to about $150 “overnight.” She applied for Optum’s temporary funding assistance program, and after some difficulty and back and forth with the company, she ultimately received a total of $756,900 in financial assistance.
Former Senator Bob Casey Jr., D-Pa., shared Meyer’s story during the congressional hearing in May. He asked Witty about the company’s approach to the repayment process.
“I’d like to absolutely confirm to you and Dr. Meyer that we have no intention of asking for loan repayment until after she determines that her business is back to normal,” Witty told lawmakers. “Even then, we would not look for repayment until 45 business days – 60 calendar days – after that and there would be no interest and no fee associated with that loan.”
“So it would be a determination she makes?” Casey asked.
“That’s absolutely right,” Witty said.
Meyer said that’s not what happened.
UnitedHealth Group Inc. headquarters stands in Minnetonka, Minnesota, U.S.
Mike Bradley | Bloomberg | Getty Images
She received a notice from Optum on Jan. 24, which was viewed by CNBC, that requested repayment since “the service disruption has ended for most clients.” Meyer said she called and told the company she was “not in any position to pay.”
Meyer claims that her practice lost more than $1 million in revenue due to the Change Healthcare cyberattack. She told CNBC the figure was based on a forensic financial analysis her practice carried out by comparing its charges against payments over recent years. The $1.2 million figure accounts for losses across all its insurers, not just UnitedHealthcare, Meyer said.
On April 1, Meyer received another notice requesting immediate repayment within five business days. The letter was addressed to Meyer. But the name of the practice on the letter, Insight Counseling, as well as the total amount due, $925,200, were incorrect.
Meyer said she called Optum again and was told the company made a mistake, but that she had five days to repay her actual total of $750,000. At that point, the company would start withholding her UnitedHealthcare payments, which she described as a “shakedown.”
Meyer said her practice typically receives annual claims payments of about $150,000 to $200,000 from UnitedHealthcare.
“I guess I’ll just let them take those payments back for the next three years until they get their money back,” she told CNBC.
In a post on LinkedIn on Thursday, Meyer wrote that she and her team “made a plan to leave the least amount of money in the account set up to receive payments from UnitedHealthcare. If it isn’t there, they can’t get it.”
‘Very frustrating experience’
Dr. Purvi Parikh, an allergist and immunologist with a private practice in New York, shared a similar story.
Parikh’s practice received about $440,000 in funding assistance after the breach. She said she started getting repayment notices late last year, and that Optum was threatening to offset claims payable to the practice.
“We were already hit very hard by the Change Healthcare hack,” Parikh said in an interview. “Now on top of that, they’re asking for all of this money back or they’re going to hold future payments ransom. It’s just been a very frustrating experience dealing with Optum.”
Parikh’s practice requested a one-month extension on its final payment of $101,650 in January to try and keep UnitedHealth from withholding other payments. In the email request, Parikh’s colleague wrote that “it has been quite difficult to recover financially.”
Optum granted Parikh’s practice the extension.
“People don’t just have that amount of money just sitting around,” Parikh said. “We’ve paid everything back, but it wasn’t without hardship.”
A physician who runs a pediatric practice in New Jersey said UnitedHealth has already started withholding payments from the organization. The practice received more than $500,000 in funding assistance following the Change Healthcare breach.
The doctor, who asked not to be named due to the sensitive nature of the situation, said the practice began receiving phone calls and emails from Optum requesting repayment beginning late last year. The group indicated that it didn’t have the money, but would set up a payment plan and had begun the process.
But the doctor said its billing department noticed that UnitedHealth had already started holding back claims payments. In its explanation of benefits, which details what an insurer will cover, the doctor said the company has a line that reads, “UnitedHealthcare is withholding payment for Optum.”
WATCH: Health and Human Services Department opens probe into hack at UnitedHealth’s Change Healthcare
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