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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Elon Musk
Elon Musk: Self-sustaining city on Mars is plausible in 25-30 years
Musk noted that true self-sufficiency requires Mars to develop “all the ingredients of civilization.”
Elon Musk has stated that a self-sustaining human settlement on Mars could be established in 25-30 years, provided launch capacity increases dramatically in the coming decades.
Speaking at the All-In Summit, the SpaceX CEO said building a self-sufficient colony depends on exponential growth in “tonnage to Mars” with each launch window, highlighting Starship’s role as the company’s pathway to interplanetary initiatives.
Mars settlement goals
Musk noted that true self-sufficiency requires Mars to develop “all the ingredients of civilization,” from food production to microchip manufacturing. Starship Version 3 is expected to support the first uncrewed Mars test flights, while future iterations could reach 466 feet in height and deliver larger payloads critical for settlement. Ultimately, Musk stated that an aggressive timeline for a city on Mars could be as short as 30 years, as noted in a Space.com report.
“I think it can be done in 30 years, provided there’s an exponential increase in the tonnage to Mars with each successive Mars transfer window, which is every two years. Every two years, the planets align and you can transfer to Mars.
“I think in roughly 15, but maybe as few as 10, but 10-15-ish Mars transfer windows. If you’re seeing exponential increases in the tonnage to Mars with each Mars transfer window, then it should be possible to make Mars self-sustaining in about call it roughly 25 years,” Musk said.
Starship’s role
Starship has flown in a fully stacked configuration ten times, most recently in August when it completed its first payload deployment in orbit. The next flight will close out the Version 2 program before transitioning to Starship Version 3, featuring Raptor 3 engines and a redesigned structure capable of lifting over 100 tons to orbit.
While SpaceX has demonstrated Super Heavy booster reuse, Ship reusability remains in development. Musk noted that the heat shield is still the biggest technical hurdle, as no orbital vehicle has yet achieved rapid, full reuse.
“For full reusability of the Ship, there’s still a lot of work that remains on the heat shield. No one’s ever made a fully reusable orbital heat shield. The shuttle heat shield had to go through nine months of repair after every flight,” he said.
News
SpaceX is partnering with chipmakers to enable Starlink satellite-to-cell service
President Gwynne Shotwell outlined the effort during a space industry conference in Paris.
SpaceX is working with microchip manufacturers to integrate satellite-connectivity hardware into smartphones, advancing its plan for direct-to-device services through Starlink.
The move follows the company’s $17 billion acquisition of wireless spectrum from EchoStar Corp., a deal that positions SpaceX to operate more independently of traditional telecom carriers.
President Gwynne Shotwell outlined the effort during a space industry conference in Paris this week, as noted in a Bloomberg News report.
Starlink direct-to-device
Starlink currently serves millions of customers in over 100 countries, primarily through ground-based dishes. The company, however, is now expanding into satellite-to-cell service, which should enable unmodified phones to connect directly with orbiting satellites. While SpaceX has a partnership with T-Mobile US, the EchoStar spectrum purchase gives it more control to negotiate with global carriers on its own terms.
“We’re working with chip manufacturers to get the proper chips in phones,” the SpaceX President stated. “We will now be initiating discussions with telcos in a different way now. Now it’s our spectrum, but we want to work with them, almost providing capacity and wholesaling capacity to their customers.”
The company plans to launch satellites capable of supporting its direct-to-device business within two years, with early mobile phone testing expected by late 2026.
Starship program continues test flights
Shotwell also addressed SpaceX’s Starship program, which recently completed its 10th test flight in August. She said the mission met all objectives, providing a critical morale boost to teams after a challenging development year.
“My Starship team needed that win,” Shotwell noted. “Development programs always are kind of a 24/7 operation, and I was really pleased for them.”
SpaceX is planning to fly one more iteration of the current Starship prototype, known as V2, before transitioning to the next-generation V3 vehicle. That version, expected to debut late this year or early 2026, is designed to be more capable and support eventual crewed missions to the Moon and Mars.
“The V3, which we want to fly hopefully late this year, but maybe early next year, is really the vehicle that could take humans to the moon and Mars,” Shotwell stated.
News
U.S. Judge dismisses lawsuit against SpaceX Starship Boca Chica launch site
The ruling found that the FAA had met its obligations in reviewing the potential environmental effects of Starship launches.
A U.S. district court judge has dismissed a lawsuit brought by conservation groups challenging the Federal Aviation Administration’s approval of SpaceX’s expanded rocket launch operations in Boca Chica, Texas.
The ruling, issued Monday, found that the FAA had met its obligations in reviewing the potential environmental effects of Starship launches.
FAA review withstands legal challenge
The lawsuit centered on whether the FAA properly assessed the impact of SpaceX’s operations on endangered wildlife, including ocelots, jaguarundis, and Kemp’s Ridley sea turtles, as noted in a report from The Guardian. The plaintiffs argued that noise, light pollution, and construction activity degraded the surrounding habitat, which also serves as nesting grounds for threatened shorebirds.
The lawsuit cited SpaceX’s April 2023 Starship test, which destroyed its launchpad and scattered debris across a large area. The blast reportedly ignited a grassfire and damaged wildlife habitats, including a bobwhite quail nest.
Judge Carl Nichols, for his part, ruled that the FAA had satisfied its obligation“to take a hard look at the effects of light on nearby wildlife.” The decision effectively cleared a regulatory hurdle for SpaceX, which has been working to expand Starship launch activity at its Boca Chica facility.
A continued ramp
SpaceX continues to scale its operations nationwide. Beyond Starship, the company is also seeking approval to nearly double Falcon rocket launches from Vandenberg Space Force Base in California, from 50 annually to 95.
Former President Trump has also shared his intention to increase U.S. launch capacity, setting a target for substantial growth by 2030. Considering that SpaceX is by far the world’s dominant launch provider, Trump’s support for more launches will likely benefit the private space company.
For now, at least, the ruling should allow continued expansion at a time when Starship remains central to long-term goals such as Mars missions and NASA’s Artemis program.
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