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SpaceX to shrink, tweak Starship’s forward flap design, says Elon Musk

Elon Musk says that SpaceX is redesigning Starship's forward flaps. (NASASpaceflight - bocachicagal)

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SpaceX CEO Elon Musk says that there is a “slight error” with the current design of Starship’s forward flaps, necessitating a few small but visible changes on future prototypes of the spacecraft.

Measuring 9m (30 ft) wide and approximately 50m (~165 ft) from tip to tail, Starship is the combined upper stage, spacecraft, tanker, and lander of a two-stage, fully-reusable rocket with the same name. While SpaceX has a long ways to go to achieve it, the company’s ambition is for Starship and its Super Heavy booster to be the most easily and quickly reusable spacecraft and rocket booster ever built, nominally enabling the same-day reuse of both.

Beyond a Space Shuttle-style heat shield of blankets and ceramic tiles, the Starship upper stage is meant to achieve that reusability by descending through the atmosphere and landing unlike any other spacecraft, plane, or rocket ever flown. Instead of flying, gliding, or knifing through the atmosphere nose or tail-first, Starship freefalls perpendicular to the ground for the last few dozen kilometers (~10-20 mi) before aggressively flipping into a vertical orientation at the last second and landing propulsively on its tail. Now, according to Elon Musk, two of the four ‘flaps’ that largely make that exotic maneuver possible are set for a small but significant redesign.

Over the course of five suborbital test flights of full-scale Starship prototypes completed between December 2020 and May 2021, SpaceX took that exotic landing concept from the drawing board and subscale wind tunnel testing to reality. Though four of those five tests ended in destruction, their respective Starship prototypes really only failed in the last 15-30 seconds of test flights that were more than six minutes long.

After reaching an apogee of 10-12.5 km (~6.2-7.8 mi) over the course of some four and a half minutes, all five Starship prototypes successfully shut down their Raptor engines, tipped over onto their bellies, and then used a combination of small pressurized gas thrusters and four large flaps to stably fall back to Earth. Much like a skydiver can tweak their body, arms, and legs to control their orientation and attitude, Starship uses two pairs of forward and aft flaps to achieve a very similar level of control.

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Thanks to Starship’s significant surface area and relatively low mass shortly before landing, that unprecedented freefall-style descent naturally slows the rocket to just 100-200 mph (~50-100 m/s) while simultaneously allowing SpaceX to avoid the massive complexity and added mass of structural wings or fins like those on the Space Shuttle. Further, whereas the Shuttle used its wings to glide (albeit like a brick) and land on very long runways, Starship is designed to use three of its six Raptor engines to flip into a vertical orientation and land much like SpaceX’s own spectacularly successful Falcon boosters.

During the actual process of reentry, in which Starship uses a heat shield made up of ~15,000 ceramic tiles to slow from orbital (Mach 25 or ~7.5 km/s) to subsonic speeds, those same flaps also come in useful to control the vehicle’s angle of attack and thus the degree of extreme heating experienced. According to Musk, to improve the moment arm (i.e. leverage or, all else equal, torque) of Starship’s forward flaps and reduce or remove undesirable aerodynamic characteristics, SpaceX is going to shrink those forward flaps further, move them closer together and more towards the tip of Starship’s nose, and angle them toward the ship’s leeward side (back).

Apparently, those relatively minor changes mean that a portion of Starship’s forward flaps will no longer be directly subjected to reentry heating, potentially allowing SpaceX to entirely remove static “aerocovers” that wrap around the ship’s flaps to prevent superheated plasma and gas from reaching sensitive components. Ironically, SpaceX’s thermal protection team completed the installation of heat shield tiles on one of those forward flap aerocovers for the first time ever just a few days ago – a structure and portion of heat shield that will apparently no longer be needed on future Starships.

For now, though, it looks like Ship 20 will attempt Starship’s first orbital launch with its now-outdated forward flaps. Depending on how far along Ship 21 production is, the next prototype could feasibly sport that new flap design.

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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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Elon Musk is setting high expectations for Tesla AI5 and AI6 chips

Musk confirmed this week that Tesla had just completed a design review for AI5.

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Image used with permission for Teslarati. (Credit: Tom Cross)

Elon Musk is setting high expectations for Tesla’s in-house silicon program. As per Musk in a set of recent posts on X, Tesla’s AI5 and AI6 will be game-changing. 

Tesla’s AI5 and AI6 are incredibly important for Tesla’s future, which will likely be built on the back of very high-volume products like Optimus and the Cybercab.

Musk sets high expectations

Musk confirmed this week that Tesla had just completed a design review for AI5, which will initially be manufactured by TSMC in Taiwan before production ramps in Arizona. As per Musk, consolidating Tesla’s chip design efforts into one architecture has allowed the company to focus its silicon talent on delivering a single high-performance platform. 

“Just had a great design review today with the Tesla AI5 chip design team! This is going to be an epic chip. And AI6 to follow has a shot at being the best (by) AI chip by far. Switching from doing 2 chip architectures to 1 means all our silicon talent is focused on making 1 incredible chip. No-brainer in retrospect,” Musk wrote in his post.

In a follow-up post, the CEO also stated that the company’s upcoming AI5 chip “will probably be the best inference chip of any kind” for models below ~250 billion parameters, with the “lowest cost silicon and best performance per watt.” Musk added that AI6, which follows AI5, “has a shot at being the best AI chip by far.”

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AI6 as Dojo’s successor

While AI5 is nearing production, Musk has also pointed to AI6 as Tesla’s next major target. The chip will be manufactured at Samsung’s upcoming Texas facility, part of a multibillion-dollar deal to support Tesla’s next-generation products such as the Cybercab and the Optimus humanoid robot. Musk also noted that AI6 could effectively replace Project Dojo as Tesla’s training platform, given its potential for both inference and training workloads.

Industry veterans have echoed this view, with former Apple and Rivian engineer Phil Beisel suggesting that “AI6 is now Dojo.” Musk appeared to agree, responding with a “bullseye” emoji. Musk has also noted on X that he would personally be walking the line in Samsung’s upcoming AI6 factory in Texas, to make sure that the facility’s output is accelerated according to Tesla’s requirements. 

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Elon Musk: Neuralink could restore partial vision to the blind next year

The executive posted the update on social media platform X.

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Credit: Steve Jurvetson/Twitter

Elon Musk has suggested that Neuralink could attempt to restore limited sight to visually impaired patients as early as 2026. 

The executive posted the update on social media platform X amid news of Neuralink’s first successful Telepathy implants outside the United States. 

Blindsight trials

In a response to a post from Neuralink’s official X account about its first Canadian patients, Musk wrote that the company is “Aiming to restore (limited) sight to the completely blind next year.” The update was well-received on social media, as the device would most likely provide notable quality of life improvements to patients. Neuralink’s current implant, Telepathy, is already changing lives today, and the same will likely be true for Blindsight.

This was not the first time that Musk has provided an update to Neuralink’s Blindsight trials. Earlier this year, Musk told the Qatar Economic Forum that the first human implantation of Blindsight could occur early 2026, potentially in the United Arab Emirates. Neuralink has explored collaboration with the Cleveland Clinic Abu Dhabi to perform the initial surgery. Blindsight has also received a “breakthrough device” designation from the US FDA, hinting at the implant’s development.

Blindsight’s potential

Musk has previously described Blindsight as Neuralink’s brain-computer interface (BCI) designed to restore vision. During Neuralink’s 2022 Show & Tell event, Musk stated that Blindsight would target the brain’s visual cortex, bypassing damaged eyes entirely to generate visual perception. This means that vision could be restored even for people who were born blind. 

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“The first two applications we’re going to aim for in humans are restoring vision, and I think this is notable in that even if someone has never had vision ever, like they were born blind, we believe we can still restore vision. The visual part of the cortex is still there. Even if they’ve never seen before, we’re confident they could see,” Musk said.

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Sweden Mediation Institute throws in the towel on Tesla vs IF Metall union conflict

After nearly two years, the union’s strike has become the country’s longest labor dispute to date.

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Credit: @NicklasNilsso14/X

Sweden’s Mediation Institute has formally ended its efforts to resolve the conflict between Tesla Sweden and trade union IF Metall. After nearly two years, the union’s strike has become the country’s longest labor dispute to date. 

Launched 677 days ago by the IF Metall union, the strike was intended to push Tesla Sweden into signing a collective agreement. Tesla Sweden, however, remained firm, maintaining that its working conditions are already better than union standards.

Mediation Institute withdraws

The state-run Mediation Institute, which had been involved early in the strike, confirmed this week that it was officially closing the case. The two parties have had several meetings, but neither side has been able to come to an agreement.

Director General Irene Wennemo described the effort as unprecedented in difficulty in a comment to Ekot. “We have tried in every possible way to get the parties to come closer to each other in a way that allows this conflict to end. But now we have come to the end of the road and have realized that it is just as good to end the case,” she told the Swedish outlet.

Union signals flexibility

The mediators noted in their final report that Tesla Sweden had limited authority in the talks, with key decisions appearing to rest with executives in the United States. The situation, they stated, created barriers to compromise that made the conflict “unlike anything else.” Tesla has maintained throughout that its Swedish workers already receive strong benefits and protections without the need for a formal collective agreement, as noted in a CarUp report.

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IF Metall, for its part, has begun hinting that it was open to alternatives. This was highlighted by Union Chair Marie Nilsson, who noted that while the preferred outcome of the country’s longest strike in history is a signed agreement, “other alternative solutions” are now on the table. “You can do it in different ways. The easiest thing would be to sign a collective agreement. But when that is not possible, we have to find other alternative solutions as well, so we are open to discussion,” the union official stated.

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