SpaceX
SpaceX goes all-in on steel Starship, scraps expensive carbon fiber BFR tooling
In a wholly unforeseen turn of events, SpaceX has taken the extraordinary step of permanently scrapping both its Port of Los Angeles-based BFR development tent and what seem to be the majority of what it contained, irreparably destroying custom-built tooling meant to support the fabrication of carbon composite BFR spaceships and boosters.
Likely worth anywhere from several to tens of millions of dollars (USD), SpaceX’s advanced BFR production tools were procured from industry-expert Ascent Aerospace sometime in 2017 before being officially delivered to the rocket company’s newly-erected Port of LA tent around April 2018. Situated at the port specifically due to logistical concerns about the high cost of transporting 9m/30ft-diameter objects from SpaceX’s main Hawthorne facilities to a barge for transport east, the company has decided to unequivocally destroy its aerospace-grade composite tooling less than 12 months after accepting delivery. Put simply, this is the best evidence yet that SpaceX – willing or not – has gone all-in on build Starship and Super Heavy out of stainless steel less than six months after CEO Elon Musk began to hint at the program’s utterly radical pivot.
From the very beginning of SpaceX and Elon Musk’s serious pursuit of an entirely reusable launch vehicle capable of transporting dozens of astronauts and passengers to and from Earth and Mars, the plan had been to build the vast majority of the rocket’s booster and spacecraft structures out of advanced carbon fiber composite materials. Above all else, this fundamental architecture was motivated largely by the significant performance gains a rocket could achieve by replacing traditional aluminum tanks and structures with carbon fiber.
For a rocket (and especially an orbital spaceship) meant to somehow make Earth-Mars transport both routine and at least minutely affordable, focusing primarily on the optimization of the mass of cargo delivered relative to the empty weight of the spaceship and booster made (and still does make) a great deal of sense. Assuming that the reusability of a system is roughly constant, the only conceivable way to further lower the cost of price per unit of cargo or passenger ticket would be to increase the usable cargo/passenger capacity for each individual launch, making an extremely light and high-performance rocket the low-hanging fruit target.
The centrality of carbon fiber composites remained with SpaceX’s Sept. 2017 iteration of BFR, downsized by 25% to a diameter of 9m (~30 ft). Around six months later, that commitment to composites was further solidified by the delivery of the first 9m-diameter carbon fiber tooling in March or April 2018. The tooling used to mold and
In the subsequent months of 2018, SpaceX’s BFR and composite R&D team spent tens of thousands of hours building out an ad-hoc advanced composites workshop inside a temporary tent in an industrial area, and ultimately managed to build a number of full-scale carbon fiber segments, including at least one large tank barrel section and the beginnings of a tank dome. In September 2018, that progress was partially revealed alongside the announcement that Japanese billionaire Yasuka Maezawa had purchased the first crewed lunar launch of BFR for several hundred million dollars, set to occur no earlier than 2023.
Two months after indicating that the first BFR “airframe/tank barrel section” would be built out of a “new carbon fiber material”, Musk provided the very first teaser for a “counterintuitive” development that would later be identified as the CEO’s decision to wholly replace BFR’s proposed used of composites with stainless steel and an advanced metallic heat shield. Still more than a little controversial and hard to follow almost half a year later, the feeling at the time was that SpaceX’s eccentric leader had decided to throw away more than 24 months of composite BFR design and development work for an almost entirely unproven alternative approach.
For better or for worse, it appears that SpaceX (or maybe just Musk) has quite literally trashed the most concrete demonstration of a prior commitment to advanced carbon fiber composites, scrapping the vast majority of its composite tooling and perhaps even the prototype BFR segments built in 2018.
It remains to be seen whether the now-permanent decision to pursue a stainless steel design in place of carbon fiber was a very expensive mistake, a stroke of genius, or something in between, However, the undeniably brisk progress made with the BFR’s steel variant in last four or so months bodes well – at a minimum – for Musk’s optimism that this radical change will ultimately result in an operational vehicle far sooner (and presumably cheaper) than the composites route.
Generally speaking, it seems safe to – on the face of it – agree with Musk’s argument that steel should ultimately lend itself far more easily to reusability thanks to its high tolerance for extreme temperatures. Unlike Falcon 9’s aluminum structures (and even the most exotic, advanced carbon fiber composites), certain varieties of stainless steel can weather heating approaching that experienced during orbital reentry with minimal erosion or damage to its mechanical properties. As Musk puts it, the Super Heavy booster’s suborbital trajectory could require almost no heat shielding – and perhaps even paint – at all.
Only time will tell whether the inevitably harsher realities of real-life engineering are so kind. In the meantime, SpaceX is perhaps just hours away from the first attempted static-fire test of a Raptor installed on something approaching flight-hardware, in this case a full-scale Starship hop test prototype.
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News
SpaceX to debut new Dragon capsule in Axiom Space launch
Ax-4’s launch marks the debut of SpaceX’s latest Crew Dragon and pushes Axiom closer to building its own space station.
Axiom Space’s Ax-4 mission targets the International Space Station (ISS) with a new SpaceX Crew Dragon capsule.
The Axiom team will launch a new SpaceX Dragon capsule atop a Falcon 9 rocket from NASA’s Kennedy Space Center in Florida on Wednesday at 8:00 a.m. EDT (1200 GMT). The Ax-4 mission launch was initially set for Tuesday, June 10, but was delayed by one day due to expected high winds.
As Axiom Space’s fourth crewed mission to the ISS, Ax-4 marks the debut of an updated SpaceX Crew Dragon capsule. “This is the first flight for this Dragon capsule, and it’s carrying an international crew—a perfect debut. We’ve upgraded storage, propulsion components, and the seat lash design for improved reliability and reuse,” said William Gerstenmaier, SpaceX’s vice president of build and flight reliability.
Axiom Space is a Houston-based private space infrastructure company. It has been launching private astronauts to the ISS for research and training since 2022, building expertise for its future station. With NASA planning to decommission the ISS by 2030, Axiom has laid the groundwork for the Axiom Station, the world’s first commercial space station. The company has already begun construction on its ISS replacement.
The Ax-4 mission’s research, spanning biological, life, and material sciences and Earth observation, will support this ambitious goal. Contributions from 31 countries underscore the mission’s global scope. The four-person crew will launch from Launch Complex 39A, embarking on a 14-day mission to conduct approximately 60 scientific studies.
“The AX-4 crew represents the very best of international collaboration, dedication, and human potential. Over the past 10 months, these astronauts have trained with focus and determination, each of them exceeding the required thresholds to ensure mission safety, scientific rigor, and operational excellence,” said Allen Flynt, Axiom Space’s chief of mission services.
The Ax-4 mission highlights Axiom’s commitment to advancing commercial space exploration. By leveraging SpaceX’s Dragon capsule and conducting diverse scientific experiments, Axiom is paving the way for its Axiom Station. This mission not only strengthens international collaborations but also positions Axiom as a leader in the evolving landscape of private space infrastructure.
SpaceX
SpaceX Dragon to carry Axiom’s Ax-4 crew for ISS research
On June 10, Axiom’s Ax-4 mission heads to the ISS on a SpaceX Dragon capsule. It’s a historic return to space for India, Poland & Hungary.
Axiom Space’s Ax-4 mission, launched on a SpaceX Dragon spacecraft, will carry a historic international crew to the International Space Station (ISS) next Tuesday, June 10, from NASA’s Kennedy Space Center in Florida.
SpaceX’s Dragon capsule was recently photographed preparing for the Ax-4 launch. The Dragon will dock at the ISS on June 11 at approximately 12:30 p.m. ET for a 14-day mission focused on groundbreaking microgravity research.
The Ax-4 crew will be led by Commander Peggy Whitson from the United States. It includes Pilot Shubhanshu Shukla from India and mission specialists Sławosz Uznański-Wiśniewski from Poland and the European Space Agency and Tibor Kapu from Hungary. This mission marks a historic return to human spaceflight for India, Poland, and Hungary as each nation sends its first government-sponsored astronauts in over 40 years.
“With a culturally diverse crew, we are not only advancing scientific knowledge but also fostering international collaboration. Our previous missions set the stage, and with Ax-4, we ascend even higher, bringing more nations to low-Earth orbit and expanding humanity’s reach among the stars,” Whitson noted.
The Ax-4 mission’s research portfolio will be Axiom’s most extensive. It includes 60 scientific studies from 31 countries, including the U.S., India, Poland, Hungary, Saudi Arabia, Brazil, Nigeria, the UAE, and Europe. These studies will advance knowledge in human research, Earth observation, life, and biological and material sciences. Key investigations include supporting astronauts with insulin-dependent diabetes, examining microgravity’s impact on the brain, and studying cancer growth, particularly triple-negative breast cancer. Additional research will explore blood stem cells, joint health, blood flow, and astronaut readiness using wearable devices, iPhone software, and AWS Snowcone analytics.
Axiom Space’s partnerships with research organizations and academic institutions aim to deepen understanding of spaceflight’s effects on the human body, with potential applications for Earth-based healthcare. The Ax-4 mission underscores Axiom’s role in redefining access to low-Earth orbit, fostering global collaboration, and advancing microgravity research. As SpaceX’s Dragon enables this historic mission, it reinforces the company’s pivotal role in commercial spaceflight and scientific discovery.
Elon Musk
SpaceX to decommission Dragon spacecraft in response to Pres. Trump war of words with Elon Musk
Elon Musk says SpaceX will decommission Dragon as a result of President Trump’s threat to end his subsidies and government contracts.
SpaceX will decommission its Dragon spacecraft in response to the intense war of words that President Trump and CEO Elon Musk have entered on various social media platforms today.
President Trump and Musk, who was once considered a right-hand man to Trump, have entered a vicious war of words on Thursday. The issues stem from Musk’s disagreement with the “Big Beautiful Bill,” which will increase the U.S. federal deficit, the Tesla and SpaceX frontman says.
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The insults and threats have been brutal, as Trump has said he doesn’t know if he’ll respect Musk again, and Musk has even stated that the President would not have won the election in November if it were not for him.
President Trump then said later in the day that:
“The easiest way to save money in our Budget, Billions and Billions of Dollars, is to terminate Elon’s Government Subsidies and Contracts. I was always surprised that Biden didn’t do it!”
Musk’s response was simple: he will decommission the SpaceX capsule responsible for transporting crew and cargo to the International Space Station (ISS): Dragon.
🚨 Elon says Dragon will be decommissioned immediately due to President Trump’s threats to terminate SpaceX’s government contracts https://t.co/XNB0LflZIy
— TESLARATI (@Teslarati) June 5, 2025
Dragon has completed 51 missions, 46 of which have been to the ISS. It is capable of carrying up to 7 passengers to and from Earth’s orbit. It is the only spacecraft that is capable of returning vast amounts of cargo to Earth. It is also the first private spacecraft to take humans to the ISS.
The most notable mission Dragon completed is one of its most recent, as SpaceX brought NASA astronauts Butch Wilmore and Suni Williams back to Earth after being stranded at the ISS by a Boeing Starliner capsule.
SpaceX’s reluctance to participate in federally funded projects may put the government in a strange position. It will look to bring Boeing back in to take a majority of these projects, but there might be some reluctance based on the Starliner mishap with Wilmore and Williams.
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