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SpaceX aces fourth Starship flight test

Starship launches on its 4th flight test (Credit SpaceX)

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SpaceX successfully launched and landed its Super Heavy booster and Starship on its fourth integrated flight test, with each making a soft splashdown in the water.

Starship took to the skies at 7:50 am CT from a foggy Starbase, Texas, in an effort to surpass previous flight milestones.

As the countdown hit zero, 32 of 33 Raptor engines on the Super Heavy booster lit, with the outlier being an engine on the outer ring. Despite the engine out, the booster still ascended with ease away from the launch mount and broke through the thick fog into clear blue skies with views streamed back to the ground from just above one of the grid fins.

As Starship climbed, everything continued to operate nominally all the way through the hot staging which saw Super Heavy Booster 11 shut down all but its 3 center Raptor engines as Starship 29 lit its 6 Raptor engines to pull away from the massive booster. As soon as Starship was clear, Booster 11 completed a flip and boostback burn to begin its trip for a planned soft touchdown in the Gulf of Mexico by relighting 10 Raptor engines.

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Once the boostback burn was complete, the hot staging ring was ejected to reduce the overall mass of the booster to help it survive reentry and landing. Future Super Heavy boosters will feature a lighter hot staging ring that will not be ejected. As the booster made its way back, it re-orientated to vertical and began re-entry back through the atmosphere, and unlike the Falcon 9, it does not perform an entry burn.

At around 7 minutes and 15 seconds into flight, the Super Heavy booster lit 12 out of a planned 13 engines for its landing burn, followed shortly by quite a bit of debris flying by the onboard camera, but it did not affect anything critical as seconds later Booster 11 made a successful splashdown in the Gulf of Mexico before a slow planned tip over into the water.

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As Booster 11 completed the first successful soft landing, Starship 29 fired its six Raptor engines, three sea level and three vacuum, with engine shutoff coming in at eight and a half minutes into flight. The starship then entered a long coast phase as it passed between the Florida Keys and Cuba and transited over the Atlantic Ocean, followed by Africa.

During IFT-3, live views were provided for a majority of this portion but due to an unknown issue, cameras didn’t come back until just before 37 minutes into the flight. Elon Musk posted on X that they had a data signal the entire time including live views from internal cameras.

45 minutes into the flight, the true test of Starship began as plasma started to build up, but this time, Starship was in the correct orientation, and the heatshield was facing the correct way to give the ship its best chance at survival.

As Starship descended, plasma build-up increased with callouts from mission control noting rising temperatures on the nose but all within acceptable limits. At just over 54 minutes into the flight, Starship made it further than the third flight test and into unknown territory.

Plasma builds up as Starship re-enters the atmosphere (Credit SpaceX)

57 minutes into the flight, peak heating had passed but tiles were starting to fall away from the forward flap followed by melting of the lower portion, despite this damage, Starship held strong and in the correct orientation as it descended.

Starship continued its descent and, with significant damage, still made it through to its own landing burn and performed its flip to a vertical orientation and a soft touchdown in the Indian Ocean west of Australia.

Damage to the forward flap as seen during the landing burn (Credit SpaceX)

Even with the damage inflicted on Starship, it completed all test objectives while providing SpaceX with incredibly valuable data that will be used to make the ship stronger on future test flights. The Starlink antenna also survived the entire flight which ensured this data made it back to mission control.

With this successful mission complete, SpaceX could launch the 5th flight by mid to late July and possibly even attempt a catch of the Super Heavy booster according to Elon Musk.

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Catch a replay of this epic mission below!

How do you think this flight went overall, and will the fifth flight take place by August?

Questions or comments? Shoot me an email at rangle@teslarati.com, or Tweet me @RDAnglePhoto.

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Launch journalist, specializing in launch photography. Based on the Space Coast, a short drive from Cape Canaveral and the SpaceX launch pads.

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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.

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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.

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.

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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.

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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.

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SpaceX Terafab rendering

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.

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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.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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