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SpaceX CEO Elon Musk kills mini BFR spaceship 12 days after announcing it

The BFR spaceship - in its 2018 design iteration - departs Earth. (SpaceX)

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Less than two weeks after SpaceX CEO Elon Musk announced that Falcon 9’s “second stage [would] be upgraded…like a mini-BFR Ship” to prove lightweight heatshield and hypersonic control surface technologies, Musk took to Twitter to assert that the mini BFR spaceship project was dead, despite having stated that SpaceX was working to launch that test article into orbit as early as June 2019 just 12 days prior.

From a public perspective, the status of SpaceX’s next-gen rocket program (known as BFR) is effectively up in the air after several cryptic and seemingly contradictory statements from the company’s CEO and chief engineer.

On Nov. 17, Musk tweeted that BFR – last updated in September 2018 alongside a statement that “this is [likely] the the final iteration [of BFR] in terms of broad architectural decisions” – had already been redesigned, going so far as to describe it as a “radical change”. What that radical design change might be is almost entirely unclear, although Musk has now twice stated that the purpose of these changes (and the whiplash-inducing cancellation of the mini-spaceship) is to “accelerate BFR”.

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As of now, SpaceX appears to have just completed a massive 9-meter diameter composite tank dome in the company’s temporary Port of Los Angeles tent, where a small but growing team of engineers and technicians are working to realize some version of the company’s next-generation rocket. That group has been working in near-silence for the better part of a year and has accepted delivery of and set up a wide range of custom-built tooling for carbon composite fabrication, and has even managed to get that tooling producing massive composite parts that are expected to eventually make up the structure of a spaceship prototype.

That prototype would eventually be shipped to South Texas, where SpaceX is constructing an entirely new facility from scratch to test the design, technology, and operation of the first full-scale BFR spaceship (BFS). As of a few months ago, the plan was to begin those hop tests before the end of 2019, but it’s no longer clear if SpaceX still intends to build a prototype spaceship to conduct hops and high-speed, high-altitude test flights.

Responsibly building giant rockets

One can only hope that the SpaceX employees tasked with bringing an already monumentally difficult idea from concept to reality are learning about these earth-shaking, “radical” decisions and changes through a medium other than Twitter. If those senior engineers and technicians are not extensively forewarned and given some say in these major system-wide decisions, it’s hard to exaggerate the amount of time, effort, and resources potentially being wasted (or at least misdirected).

There is undoubtedly something to be said for getting complex and difficult things as right as possible on the first serious try, especially when the sheer expense of the task at hand might mean that there is only one real chance to try. Still, it’s not particularly encouraging when a three-year-old hardware development program marked by several major design iterations is still experiencing anything close to “radical change”. After multiple years of concerted effort, BFR still appears to be in some sort of design limbo, where a constant and haphazard stream of on-paper changes act as a near-insurmountable hurdle standing in the way of a completed “good enough” blueprint that can begin to be made real.

 

Ultimately, even if some of the worst-case scenarios described above turn out to be true, there are still many, many reasons to remain positive about SpaceX’s BFR program on the whole. The next-gen rocket’s propulsion system of choice – an advanced engine known as Raptor –  is quite mature at this point and may already be nearing initial flight readiness. Regardless of any future changes to BFR’s overall spaceship and booster structures, SpaceX technicians, engineers, and material scientists have likely gained invaluable experience in pursuit of an unprecedented 9-meter diameter rocket built almost entirely out of carbon fiber composites.

Further, it appears that quite a bit of progress has been made over the course of R&D programs related to methane-oxygen RCS thrusters (Falcon uses nitrogen), autogenous tank pressurization with gaseous methane and oxygen (Falcon uses helium), and perhaps even in-situ resource utilization (ISRU) that will be an absolute necessity to generate water, oxygen, and methane that will keep prospective Mars colonists alive and refuel spaceships for the voyage back to Earth.


For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet check out our brand new LaunchPad and LandingZone newsletters!

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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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Cybertruck

Tesla Cybertruck production snaps back after ugly supplier fight

Cybertrucks are piling up again at Giga Texas after Tesla’s court win against a parts supplier.

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Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | X
Tesla Cybertruck production resumes after supplier dispute: Credit: Joe Tegtmeyer | Youtube

Cybertruck production at Giga Texas is showing its first visible recovery since Tesla sued a supplier last month over withheld manufacturing tooling.

Aerial observer Joe Tegtmeyer flew over the Austin factory Wednesday morning and counted roughly 100 or more Cybertrucks filling the outbound lot, a sharp jump from the thin numbers seen in recent weeks. The flyover came a day after a judge granted Tesla a temporary restraining order against Angstrom Automotive Group, the parts supplier at the center of the dispute.

Tesla filed an emergency lawsuit in late July after Angstrom told the automaker it planned to close the Troy, Texas facility where Tesla’s die-cast tools, trim dies and other Cybertruck stamping equipment were housed. According to Tesla’s complaint, a shipment of 700 finished parts never left the building, and when Tesla sent representatives to retrieve its equipment, accompanied by law enforcement, they were turned away. Angstrom allegedly then asked for an extra $250,000 a week to keep operating, which Tesla’s filing described as holding its own property for ransom.

Tesla quietly made the Cybertruck even stronger

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The restraining order gives Tesla immediate right of entry to Angstrom’s facility to recover the tooling. It is temporary, with a fuller hearing still to come, but the speed of Wednesday’s rebound suggests the Angstrom shortage was indeed the main bottleneck limiting Cybertruck output. Outbound lot counts are an imperfect measure of actual production, since finished trucks can sit for days before shipping, but a lot that full after a lean stretch is a meaningful signal.

Cybertruck output at Giga Texas has fluctuated all year as Tesla worked through supply issues and introduced new trims, including a cheaper Dual Motor AWD version that drew strong early demand.

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Elon Musk

Space finally faced the people living next to its next Terafab mega-project

SpaceX confirmed Terafab’s Grimes County site is locked in, with construction starting within months.

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SpaceX and Terafab representatives sat across from Grimes County residents for the first time on Wednesday, telling a packed Commissioners Court room that the $55 billion chip manufacturing project is now a done deal at the Gibbons Creek Reservoir site.

The meeting followed a $10 million check SpaceX sent the county earlier this week, satisfying a payment deadline built into the tax abatement agreement both sides signed in June. Elon Musk shared a post on X confirming the payment, and County Judge Joe Fauth told the San Antonio Express-News his office deposited the check after it beat its deadline.

Wednesday’s session, first reported by KBTX, moved the project from paperwork to construction. Terafab representative Riley Trennell told residents the JETI tax break agreements with Iola ISD and Anderson-Shiro CISD are signed and active, and that civil work and foundation prep are starting almost immediately. Renderings of the facility could be released within days, he said, with construction beginning within months.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

Musk first announced Terafab in March as a joint venture between Tesla, SpaceX and xAI aimed at producing over a terawatt of AI compute annually, an amount that dwarfs the roughly 20 gigawatts the entire global chip industry produces today. Intel joined as a manufacturing partner in April. Musk has said the project needed its own day in the spotlight rather than being squeezed into an earnings call, and for months the Grimes County site remained unconfirmed even as reporting pointed there.

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SpaceX attorney Buck Brannon used Wednesday’s meeting to note that the company’s abatement is roughly 78 percent, not the 100 percent some earlier reports suggested. In exchange, SpaceX will pay Grimes County a fixed $20 million a year for 35 years, a total of $710 million, which Brannon said exceeds the $14 million Tesla paid Travis County in 2025.

SpaceX also addressed environmental concerns that have followed the project since Musk’s Terafab partnership with Intel was announced. Representatives said Terafab will not raise electric bills for other ratepayers, will not deplete local water supplies and will not draw down the Navasota River. SpaceX confirmed it owns the Navasota River pumping station, which it plans to use to divert stormwater into the Gibbons Creek Reservoir, and said it will build its own natural gas plants to power the facility rather than pulling from the ERCOT grid.

Grimes County commissioners also approved an addendum letting county employees use ten approved AI chatbots for work, including Grok.

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Elon Musk

SpaceX has solved Starship’s biggest challenge, Elon Musk says

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Credit: SpaceX

Elon Musk has declared that SpaceX has effectively solved one of Starship’s most persistent engineering challenges: the reliability of its heat shield tiles.

During the company’s first-ever Earnings Call, the SpaceX CEO stated:

“I don’t want to jinx it or anything, but I think I would call the heat shield problem solved at this point. All indications from data and visual inspection is we have solved it. That doesn’t mean we won’t make improvements, but we do not see any technical obstacles to achieving rapid reusability at this point.”

Starship’s heat shield consists of roughly 18,000 hexagonal ceramic tiles covering the windward side of the upper stage. These tiles form the thermal protection system that shields the vehicle’s stainless-steel structure from the extreme heat of atmospheric reentry.

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During descent, atmospheric friction generates temperatures exceeding several thousand degrees Celsius and creates plasma flows capable of melting unprotected metal. The tiles absorb, radiate, and insulate against this energy, allowing the vehicle to survive and potentially fly again. Without a durable heat shield, full and rapid reusability, the cornerstone of Starship’s design for frequent launches, satellite deployments, and deep-space missions, would remain impossible.

The tiles have long been a source of difficulty. On earlier test flights, a significant number of tiles detached during ascent due to vibration, aerodynamic loads, and imperfect attachment methods using pins and adhesives. Gaps between tiles allowed hot plasma to infiltrate, causing secondary damage and hot spots on the underlying structure.

These issues echoed challenges faced by NASA’s Space Shuttle, whose ceramic tiles required extensive, labor-intensive inspections and replacements between missions, preventing rapid turnaround. SpaceX has iteratively improved materials, standardized tile shapes, refined attachment techniques, added secondary ablative layers, and tested sealing methods such as “crunch wrap” felt to close gaps.

Progress was visible across Flights 10–12, with steadily better tile retention, yet questions remained about whether the system could support the minimal-refurbishment goal of rapid reuse.

Flight 13 on July 24 provided the decisive evidence. Ship 40 flew a deliberately more demanding profile with higher dynamic pressure to stress the heat shield beyond typical operational loads. It successfully deployed 20 operational Starlink V3 satellites, the first such payload on a Starship mission, performed an in-space Raptor engine relight, and executed a controlled reentry.

Elon Musk sheds two new bits of detail on Starship after 13th test launch

Cameras on six of the satellites and onboard sensors captured extensive imagery and data of the shield throughout the flight. The ship then achieved its softest splashdown to date in the Indian Ocean, remaining intact and floating rather than breaking apart or exploding as on prior missions. This allowed drone inspections and continuous telemetry of the heat shield in near-real time.

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Post-flight analysis showed the majority of tiles remaining attached with only minor damage and limited plasma streaking at seams. Musk noted that the mission delivered “all the heat shield data we needed and then some.” Combined with visual inspections, these results underpinned his subsequent assessment that the core technical barriers to rapid reusability have been cleared. While refinements will continue, Flight 13 marked a pivotal step toward Starship’s operational future.

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