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SpaceX’s first orbital Starship begins assembly as steel heat shield passes tests

CEO Elon Musk posted a video of SpaceX engineers testing a small section of a Starship heat shield prototype. (Elon Musk/SpaceX)

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SpaceX CEO Elon Musk says that the company’s South Texas workforce has already begun to fabricate the first orbital-class Starship prototype, while Hawthorne engineers and technicians are in the midst of performing small-scale testing of the vehicle’s unprecedented stainless steel heat shield.

To be assembled out of hexagonal tiles of (presumably) stainless steel, Starship’s metallic heat shield will be one of the most crucial aspects of the orbital spacecraft, particularly with respect to ensuring that it’s extraordinarily easy to reuse. To survive extreme interplanetary-velocity reentry conditions at Mars, Earth, and beyond and remain in a functional, flight-ready condition after landing, SpaceX will need to implement the world’s first orbital-class, large-scale metallic heat shield with an immature technology known as transpirational cooling.

By quite literally drilling tiny holes (pores) into heat shield plates at the hottest parts of Starship’s hull, transpirational cooling effectively allows a large portion of the heat of reentry to be wicked away by the flash evaporation of a liquid, typically water. For SpaceX’s Starship, it’s likely that the coolant of choice would be either liquid water or liquid methane, the former of which offers better cooling per unit of mass at the cost of added plumbing complexity and spaceship mass, while the latter would make use of the same propellant fueling the ship at the cost of worse cooling per unit of mass. Either way, SpaceX will be heading into unproven territory, demanding extensive ground and flight testing to first ensure that the concept is truly viable and then to verify that it can be made as reliable and reusable as it simply has to be.

Tests like those shown on March 17th by Musk indicate that SpaceX is indeed deep into the process of extensive and often destructive testing, something the company has proven to be exceptionally good at. It’s unclear if the above test of Starship’s hexagonal heat shield tiles – likely made out of a variant of 300-series stainless steel – involved tiles with active or passive cooling, but Musk suggested that the hot-spots created with spin-forming torches reached temperatures as high as 1650 Kelvin (2500ºF/1400ºC. Unlike the ablative heat shields SpaceX is familiar with building and operating through its Crew and Cargo Dragon spacecraft, a stainless steel heat shield would be expected to almost entirely resist erosion (i.e. ablation) during extremely high-velocity reentries of at least 12-14 km/s (~31,000 mph, Mach 40+).

Meanwhile, Musk also confirmed that SpaceX has decided to skip constructing a replacement nosecone/fairing for Starhopper, a functional Starship prototype that will be used to conduct extremely short hop tests like Falcon 9’s development-era Grasshopper and F9R test articles. Over the last several weeks, SpaceX technicians have been rapidly assembling what was initially assumed to be the replacement fairing Musk had previously suggested would be built. Instead, the duo of stainless steel barrel sections – relying on steel much thinner than the heavy-duty stuff used to build Starhopper – are apparently the beginnings of the first orbital-class Starship prototype, said by Musk to be aiming for flight-readiness as early as June 2019 around two months ago.

While still an extraordinarily ambitious target for a vehicle that has yet to conduct any integrated hops or flight-tests in any form, the fact that SpaceX is began the process of building the first orbital Starship in late February could actually give the company’s engineers and technicians a fighting chance to complete Starhopper testing and Starship assembly over the next 90-100 days.

If stacked atop each other, the two new steel sections in work would likely stretch a solid 20-30 meters (65-100 ft) tall. Meanwhile, the first orbital-grade tank domes and/or conical nose section is also in the process of being welded together out of smaller segments, already fast approaching something ready to be installed inside the steel barrel sections.

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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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Starlink gets its latest airline adoptee for stable and reliable internet access

The company said it plans to “rapidly integrate Starlink into its fleet,” and that the first Starlink-equipped aircraft will enter service this Summer.

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Credit: Southwest Airlines

SpaceX’s Starlink, the satellite internet program launched by Elon Musk’s company, has gotten its latest airline adoptee, offering stable and reliable internet to passengers.

Southwest Airlines announced on Wednesday that it would enable Starlink on its aircraft, a new strategy that will expand to more than 300 planes by the end of the year.

The company said it plans to “rapidly integrate Starlink into its fleet,” and that the first Starlink-equipped aircraft will enter service this Summer.

Tony Roach, Executive Vice President, Chief Customer and Brand Officer for the airline, said:

“Free WiFi has been a huge hit with our Rapid Rewards Members, and we know our Customers expect seamless connectivity across all their devices when they travel. Starlink delivers that at-home experience in the air, giving Customers the ability to stream their favorite shows from any platform, watch live sports, download music, play games, work, and connect with loved ones from takeoff to landing.”

Southwest also said that this is just one of the latest upgrades it is making to provide a more well-rounded experience to its aircraft. In addition to Starlink, it is updating cabin designs, offering more legroom, and installing in-seat power to all passengers.

Southwest became one of several airlines to cross over to Starlink, as reviews for the internet provider have raved about reliability and speed. Over the past year, Hawaiian Airlines, United Airlines, Alaska Airlines, airBaltic, Air France, JSX, Emirates, British Airways, and others have all decided to install Starlink on their planes.

This has been a major move away from unpredictable and commonly unreliable WiFi offerings on planes. Starlink has been more reliable and has provided more stable connections for those using their travel time for leisure or business.

Jason Fritch, VP of Starlink Enterprise Sales at SpaceX, said:

“We’re thrilled to deliver a connectivity experience to Southwest Airlines and its Customers that really is similar, if not better, than what you can experience in your own home. Starlink is the future of connected travel, making every journey faster, smoother, and infinitely more enjoyable.”

Starlink recently crossed a massive milestone of over 10 million subscribers.

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Elon Musk tops Forbes’ list of America’s 250 greatest innovators

The ranking places Musk at the top of modern American innovation.

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Gage Skidmore, CC BY-SA 4.0 , via Wikimedia Commons

Elon Musk has been ranked No. 1 on Forbes’ inaugural list of America’s 250 Greatest Innovators. The ranking places Musk at the top of modern American innovation as the publication kicks off a series celebrating the nation’s 250th anniversary.

Forbes described innovation as “the grease in the economic engine” and the force that transforms industries and creates new ones. The publication highlighted that its honorees are not just inventors, but business leaders who successfully bring breakthroughs to market.

Musk, 54, was ranked No. 1 in this year’s list. Forbes noted that he is “the only person in history to have founded (or grown from nearly nothing) five companies, each with multibillion-dollar valuations, each in a different industry.” Those companies include Tesla, SpaceX, Neuralink, xAI, and The Boring Company.

Forbes’ methodology began with nearly 1,000 nominees submitted by its reporters. A panel of judges, including venture capitalist Jim Breyer, journalist Kara Swisher, and strategy expert Rita McGrath, ranked candidates based on creativity, breadth, engagement, disruption, and commercial impact. Artificial intelligence tools, including ChatGPT and Gemini, were also used to assess candidates before editors finalized the rankings.

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The publication noted that more than one-third of the list consists of women and people of color, reflecting shifts in innovation and entrepreneurship over time. All individuals listed are also American citizens, though many were born abroad, including Musk himself. Musk was born in Pretoria, South Africa.

Ranked No. 2 is Jeff Bezos, 61, who Forbes credited with upending America’s $7.4 trillion retail industry through Amazon before pioneering cloud computing with Amazon Web Services. The publication highlighted that Bezos now focuses on space exploration through Blue Origin and artificial intelligence manufacturing systems at Prometheus.

At No. 3 is Bill Gates, 70, who helped launch the personal computing revolution and built Microsoft into the dominant force in workplace software. Forbes also highlighted Gates’ reinvention at age 50 as a data-driven philanthropist, including his role in helping eradicate polio from India.

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SpaceX secures win as US labor board drops oversight case

The NLRB confirmed that it no longer has jurisdiction over SpaceX.

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Credit: SpaceX

SpaceX scored a legal victory after the National Labor Relations Board (NLRB) decided to dismiss a case which accused the company of terminating engineers who were involved in an open letter against founder Elon Musk. 

The NLRB confirmed that it no longer has jurisdiction over SpaceX. The update was initially shared by Bloomberg News, which cited a letter about the matter it reportedly reviewed.

In a letter to the former employees’ lawyers, the labor board stated that the affected employees were under the jurisdiction of the National Mediation Board (NMB), not the NLRB. As a result, the labor board stated that it was dismissing the case.

As per Danielle Pierce, a regional director of the agency, “the National Labor Relations Board lacks jurisdiction over the Employer and, therefore, I am dismissing your charge.”

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The NMB typically oversees airlines and railroads. The NLRB, on the other hand, covers most private-sector employers, as well as manufacturers such as Boeing. 

The former SpaceX engineers have argued that the private space company did not belong under the NMB’s jurisdiction because SpaceX only offers services to “hand-picked customers.” 

In an opinion, however, the NMB stated that SpaceX was under its jurisdiction because “space transport includes air travel” to get to outer space. The mediation board also noted that anyone can contact SpaceX to secure its services.

SpaceX had previously challenged the NLRB’s authority in court, arguing that the agency’s structure was unconstitutional. Jennifer Abruzzo, the NLRB general counsel under former United States President Joe Biden, rejected SpaceX’s claims. Following Abruzzo’s termination under the Trump administration, however, SpaceX asked the labor board to reconsider its arguments. 

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SpaceX is not the only company that has challenged the constitutionality of the NLRB. Since SpaceX filed its legal challenge against the agency in 2024, other high-profile companies have followed suit. These include Amazon, which has filed similar cases that are now pending.

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