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Relativity Space’s first 3D-printed rocket booster passes early tests

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Relativity Space CEO Tim Ellis says that the startup’s first 3D-printed ‘Terran-1’ rocket booster has already completed a few significant tests after arriving at its Florida launch pad last month.

Terran-1 is an expendable two-stage launch vehicle that, when assembled for the first time, will measure around 33 meters (110 ft) tall, 2.3 meters (7.5 ft) wide, and weigh 9.3 tons (~20,500 lb) empty. Fueled by liquid oxygen and methane (methalox) and powered by nine small Aeon engines, the first Terran booster will produce around 90 tons (~200,000 lbf) of thrust at liftoff. Altogether, the rocket is designed to initially launch up to 1.25 tons (~2750 lb) to low Earth orbit, with plans to expand to 1.5 tons (~3300 lb) in the future. SpaceX’s Falcon 9, for context, measures 3.7 meters (12 ft) wide, 70 meters (~230 ft) tall, likely weighs around 30 tons (~65,000 lb) dry, and can launch 22.8 tons (~50,250 lb) to LEO in an expendable configuration. A single one of its nine Merlin 1D booster engines produces about as much thrust as the entire first stage of Terran-1.

While tiny in comparison, Terran-1’s booster is still a relatively large and powerful rocket, and testing it poses significant challenges. Instead of building a custom test stand elsewhere, Relativity has chosen to conduct almost all first-stage qualification testing at its Cape Canaveral Space Force Station (CCSFS) LC-16 pad. 

That plan increases the risk of the rocket damaging Relativity’s only available launch pad, significantly delaying launch preparations, but it also has the potential to save time by doubling as a launch pad shakedown. Aside from basic concrete features and foundations, LC-16 was essentially a blank slate when Relativity arrived, so qualifying the pad – virtually all of which is new and recently installed – is no small feat on its own.

LC-16, 2022. (Relativity Space)

Relativity’s first Terran-1 flight hardware has performed shockingly well. The smaller single-engine upper stage sailed through a full program of proof tests – including a full-duration static fire – shortly before shipping to LC-16. Terran-1’s first booster, meanwhile, left Relativity’s California factory and arrived at LC-16 to begin its own qualification testing in early June.

A frosty, venting Terran-1 booster is pictured during one of its first cryogenic tests. (Tim Ellis)

On June 28th, CEO Tim Ellis revealed that the booster had already completed “pneumatic proof testing” and made it through its “first propellant loading” test less than a month after arriving at LC-16. That would be fast for the first prototype of any new orbital-class rocket, but Relativity’s Terran-1 has an extremely unique feature that makes that speed even more impressive: by mass, the vast majority (85%) of the rocket was manufactured with 3D printing. In effect, most of Terran’s airframe and tanks are just giant, continuous welds that were precisely manipulated into cylinders, domes, and more. While the rough surface finish leaves something to be desired and likely reduces the overall efficiency of the rocket’s airframe, Relativity says that the composition of the metal in its printed structures is almost identical to a more traditionally-manufactured component.

Relativity’s ultimate hope is that the technical groundwork it is laying will allow it to manufacture complex and high-performance rockets with minimal human intervention, drastically lowering production costs. One day, the descendants of those semi-autonomous factories might even be used to construct rockets and other complex machines and infrastructure on Mars or other extraterrestrial destinations.

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First, though, the company needs to start successfully launching Terran-1 rockets and fully prove the concept. Up next, Relativity will likely perform a full wet dress rehearsal, a launch simulation in which the rocket is loaded with propellant and pressurized for flight. Once that step is complete, Relativity will attempt one or several static fire tests, culminating in a full-duration multi-minute static fire or “mission duty cycle.”

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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Tesla is bringing back something it took from the Model 3…for a price

“Modify your Model 3 by replacing the turn signal buttons on your steering wheel with turn signal stalks. This modification is included in the purchase price and is installed by a Tesla Service Center.”

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Credit: Tesla

Tesla is bringing back the Model 3’s turn signal stalk in China after removing the part with the refresh of the all-electric sedan early last year.

However, it is going to cost you.

In 2024, Tesla launched the Model 3 “Highland,” a refreshed version of the vehicle that included several large-scale changes. One of the most noticeable was the lack of a turn signal stalk, something the company chose to remove and instead implement turn signal buttons on the steering wheel.

The buttons were met with mixed reviews, as some drivers complained that it was too difficult to get used to them. Others had no problem with the change, noting that it was slightly more convenient for them or that they enjoyed the minimalistic look.

Now, Tesla is offering Model 3 owners in China the opportunity to replace the stalk for a price of ¥ 2,499, or about $350:

“Modify your Model 3 by replacing the turn signal buttons on your steering wheel with turn signal stalks. This modification is included in the purchase price and is installed by a Tesla Service Center.”

Tesla notes on its website that the service is available for Model 3 vehicles without stalks manufactured after February 7, 2025. Any car without a stalk that was manufactured before that date will have the service available to them in the future.

Installation can be performed at a Service Center or by the owner. However, Tesla notes that it is not responsible for any damages resulting from self-installation and recommends that the part be put in by an employee.

The cockpit of the Tesla lineup has been under intense scrutiny by the company in recent years. After a few changes to things like the stalk, steering wheel shape, and others, Tesla has usually given drivers the chance to have things reverted back to their preferences if they want.

They did this for the Model S and Model X a few years ago after implementing the yoke steering wheel.

Tesla Steering Wheel Retrofits have started, and it’s easy to get rid of your yoke

The stalk was not supposed to be removed from the Model 3 and Model Y, but Tesla chose to do so with the refresh last year.

It seems the minimalization of the cockpit, overall, is a move that prepares drivers for autonomy, as eventually, Teslas will be void of pedals, steering wheels, and any other apparatus that are used to control the car.

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Tesla launches new loaner program that owners will love

Tesla is now giving owners the opportunity to rent a vehicle from them, and it includes a few very attractive features that will have you second-guessing another loaner from insurance.

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Credit: Tesla

Tesla has launched a new loaner program that owners will love, as it resolves some concerns over a replacement vehicle while it is being repaired.

Earlier this week, Tesla launched the option to rent a Tesla loaner vehicle for just $45 per day if your vehicle is in Collision Repair. Collision repairs did not formerly warrant the issuance of loaner vehicles, as the insurance provider of the car owner would provide transportation arrangements.

Tesla is now giving owners the opportunity to rent a vehicle from them, and it includes a few very attractive features that will have you second-guessing another loaner from insurance.

The Tesla you rent while your car is in collision repair will come with free Full Self-Driving, free Supercharging, and free toll coverage, no small print included.

All things considered, this is a great deal for those who require a car for transportation while their car is being repaired.

The cost of Supercharging and Full Self-Driving alone would warrant the $45 per day price tag. Add in the tolls for those who commute on turnpikes for work or are planning an extensive trip that would require it, and it truly becomes an even more attractive deal.

Tesla has done a good job at improving its Service division over the past few years, and it truly needed it. In hopes of launching an F1-style service experience, Tesla started doing away with some of its perks, including loaner vehicles for single-day visits and even Uber credits.

Tesla’s ‘F1’ Service strategy eliminates same-day loaner vehicles, Uber credits

However, it has listened to the complaints of its owners and tried to cater an experience that is more advantageous and less of a hassle. It’s already made tremendous steps in the past few years, and this is the icing on the cake.

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SpaceX Starship Flight 10: What to expect

SpaceX implemented hardware and operational changes aimed at improving Starship’s reliability.

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Credit: SpaceX

SpaceX is preparing to launch the tenth test flight of its Starship vehicle as early as Sunday, August 24, with the launch window opening at 6:30 p.m. CT. 

The mission follows investigations into anomalies from earlier flights, including the loss of Starship on its ninth test and a Ship 36 static fire issue. SpaceX has since implemented hardware and operational changes aimed at improving Starship’s reliability.

Booster landing burns and flight experiments

The upcoming Starship Flight 10 will expand Super Heavy’s flight envelope with multiple landing burn trials. Following stage separation, the booster will attempt a controlled flip and boostback burn before heading to an offshore splashdown in the Gulf of America. One of the three center engines typically used for landing will be intentionally disabled, allowing engineers to evaluate whether a backup engine can complete the maneuver, according to a post from SpaceX.

The booster will also transition to a two-engine configuration for the final phase, hovering briefly above the water before shutdown and drop. These experiments are designed to simulate off-nominal scenarios and generate real-world data on performance under varying conditions, while maximizing propellant use during ascent to enable heavier payloads.

Starship upper stage reentry tests

The Starship upper stage will attempt multiple in-space objectives, including deployment of eight Starlink simulators and a planned Raptor engine relight. SpaceX will also continue testing reentry systems with several modifications. A section of thermal protection tiles has been removed to expose vulnerable areas, while new metallic tile designs, including one with active cooling, will be trialed.

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Catch fittings have been installed to evaluate their thermal and structural performance, and adjustments to the tile line will address hot spots observed on Flight 6. The reentry profile is expected to push the structural limits of Starship’s rear flaps at maximum entry pressure.

SpaceX says lessons from these tests are critical to refining the next-generation Starship and Super Heavy vehicles. With Starfactory production ramping in Texas and new launch infrastructure under development in Florida, the company is pushing to hit its goal of achieving a fully reusable orbital launch system.

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