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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Cybertruck
Tesla Cybertruck fleet takes over at SpaceX’s Starbase
Interestingly, the Cybertruck uses the same exterior, a stainless steel alloy, as SpaceX rockets. This synergy between the two companies and their very different products shows a very unified mentality between Musk companies.
Tesla Cybertrucks have taken over at SpaceX’s Starbase facility in Texas, as hundreds of the all-electric pickup trucks were spotted late last week rounding out a massive fleet of vehicles.
The Cybertruck fleet is geared toward replacing gas vehicles that are used at Starbase for everyday operations. The only surprise about this is that it was not done sooner:
Was just visiting. pic.twitter.com/5Q9wPPaeuH
— Derek Li (@derek1ee) October 31, 2025
Deliveries have been going on for a few weeks, as Cybertrucks have made their way across the state of Texas from Austin to Starbase so they could be included in SpaceX’s fleet of vehicles at the facility.
Interestingly, the Cybertruck uses the same exterior, a stainless steel alloy, as SpaceX rockets. This synergy between the two companies and their very different products shows a very unified mentality between Musk companies.
However, there are some other perspectives to consider as SpaceX is utilizing such a massive fleet of Cybertrucks. Some media outlets (unsurprisingly) are seeing this as a move of weakness by both Tesla and SpaceX, as the aerospace company is, in a sense, “bailing out” lagging sales for the all-electric pickup.
It’s no secret that Tesla has struggled with the Cybertruck this year, and deliveries have been underwhelming in the sense that the company was anticipating between 1 million and 2 million orders for the vehicle before it was widely produced.
A lot of things changed with the Cybertruck between its 2019 unveiling and 2023 initial deliveries, most notably, price.
The price of the Cybertruck swelled significantly and priced out many of those who had pre-ordered it. Some have weighed the option of whether this purchase was a way to get rid of sitting inventory.
However, it seems more logical to consider the fact that SpaceX was likely always going to transition to Teslas for its fleet, especially at Starship, at some point.
It doesn’t seem out of the question that one Musk company would utilize another Musk company’s products, especially considering the Cybertruck has been teased as the vehicle that would be present on Mars.
News
SpaceX successfully launches 100th Starlink mission of 2025
With 100 Starlink missions completed for 2025, space enthusiasts have noted that SpaceX has successfully launched 2,554 Starlink satellites so far this year.
SpaceX achieved its 100th Starlink mission of the year on Friday, October 31, marking another milestone for 2025.
A Falcon 9 rocket carrying 28 Starlink broadband satellites successfully lifted off from Vandenberg Space Force Base in California at 4:41 p.m. ET, carrying another 28 Starlink satellites to Low Earth Orbit (LEO).
Falcon 9 booster’s 29th flight
Roughly 8.5 minutes after liftoff, the Falcon 9’s first stage touched down on the drone ship Of Course I Still Love You in the Pacific Ocean. This marked the booster’s 29th flight, which is approaching SpaceX’s reuse record of 31 missions.
This latest mission adds to SpaceX’s impressive 138 Falcon 9 launches in 2025, 99 of which were dedicated to Starlink, according to Space.com. The company’s focus on reusing boosters has enabled this breakneck pace, with multiple launches each week supporting both Starlink’s expansion and external customers.
Starlink’s network continues massive global expansion
Starlink remains the largest active satellite constellation in history, with more than 10,000 satellites launched, nearly 8,800 of which are currently active. SpaceX recently achieved Starlink’s 10,000-satellite milestone. With 100 Starlink missions completed for 2025, space enthusiasts have noted that SpaceX has successfully launched 2,554 Starlink satellites so far this year.
Starlink, which provides high-speed, low-latency internet connectivity even to the world’s most remote areas, has been proven to be life-changing technology for people across the globe. The service is currently operational in about 150 countries, and it currently has over 5 million subscribers worldwide. From this number, 2.7 million joined over the past year.
SpaceX has revealed that it has completed 49 major milestones for NASA’s Human Landing System (HLS) program, marking significant progress in the development of the Starship lunar lander that will deliver astronauts to the Moon.
The updates were detailed in SpaceX’s new blog post To the Moon and Beyond, which was recently posted on the private space company’s official website.
As noted by SpaceX, the 49 milestones that were completed by its HLS team were “tied to developing the subsystems, infrastructure, and operations” needed to safely land humans back into the lunar surface. SpaceX noted that it has only received funding on contractual milestones that have been successfully completed, the vast majority of which have been achieved on time or ahead of schedule.
Following are highlights of SpaceX’s completed milestones, as per the company’s post.
For the first time in our existence, we possess the means, technology, and, for the moment, the will to establish a permanent human presence beyond Earth. Starship is designed to make this future a reality → https://t.co/dGAZiB4rr3 pic.twitter.com/WsTg44G3oz — SpaceX (@SpaceX) October 30, 2025
- Lunar environmental control and life support and thermal control system demonstrations, using a full-scale cabin module inhabited by multiple people to test the capability to inject oxygen and nitrogen into the cabin environment and accurately manage air distribution and sanitation, along with humidity and thermal control. The test series also measured the acoustic environments inside the cabin
- Docking adapter qualification of the docking system that will link Starship and Orion in space, an androgynous SpaceX docking system capable of serving as the active system or passive system and based on the flight-proven Dragon 2 active docking system
- Landing leg drop test of a full-scale article at flight energies onto simulated lunar regolith to verify system performance and to study foot-to-regolith interaction
- Raptor lunar landing throttle test demonstrating a representative thrust profile that would allow Starship to land on the lunar surface
- Micrometeoroid and orbital debris testing of shielding, insulation, and window panels, analyzing different material stackups that will be used to protect Starship from impact hazards and harsh thermal conditions
- Landing software, sensor, and radar demonstrations testing navigation and sensing hardware and software that will be used by Starship to locate and safely descend to a precise landing site on the Moon
- Software architecture review to define the schematic of major vehicle control processes, what physical computers they will run on, and software functions for critical systems like fault detection, caution and warning alerts, and command and telemetry control
- Raptor cold start demonstrations using both sea-level and vacuum-optimized Raptor engines that are pre-chilled prior to startup to simulate the thermal conditions experienced after an extended time in space
- Integrated lunar mission operations plan review, covering how SpaceX and NASA will conduct integrated operations, develop flight rules and crew procedures, and the high-level mission operation plan
- Depot power module demonstration, testing prototype electrical power generation and distribution systems planned to be used on the propellant depot variant of Starship
- Ground segment and radio frequency (RF) communications demonstration, testing the capability to send and receive RF communications between a flight-equivalent ground station and a flight-equivalent vehicle RF system
- Elevator and airlock demonstration, which was conducted in concert with Axiom to utilize flight-representative pressurized EVA suits, to practice full operation of the crew elevator which will be used to transfer crew and cargo between Starship and the lunar surface
- Medical system demonstration covering the crew medical system on Starship and the telemedicine capability between the ground and crew
- Hardware in the loop testbed activation for the propellant transfer flight test which uses a testbed with flight representative hardware to run simulations for the upcoming propellant transfer flight test
Ultimately, SpaceX’s message is clear. With its plans for a simplified architecture, the timeframe of the first crewed lunar landing of the current century could happen sooner than expected.
Musk definitely seems determined to prove skeptics wrong, with the CEO declaring on X that Starship will be the vehicle that would pave the way for the buildout of a base on the Moon. “Starship will build Moonbase Alpha,” Musk wrote.
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