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SpaceX CEO Elon Musk explains how Starships will return from orbit
In the near future, SpaceX wants to begin putting its first two full-scale Starship prototypes through a series of increasingly challenging test flights, eventually culminating in their first Super Heavy-supported orbital launch attempts.
SpaceX CEO Elon Musk took to Twitter over the last 48 or so hours to answer a number of questions about how exactly Starship is meant to make it through orbital reentries – by far the most strenuous period for the ship and without a doubt the single most challenging engineering problem SpaceX must tackle.
Discussed yesterday on Teslarati, SpaceX technicians began the process of attaching numerous Tesla Model S/X battery packs to a subcomponent that will eventually be installed inside Starship Mk1’s nose, offering a storage capacity of up to 400 kWh. The need for all that power (Crew Dragon relies on a few-kWh battery) is directly related to Starship Mk1’s methods of reentry and recovery, recently described in detail by Elon Musk.
As noted above, ~400 kWh of batteries are needed to power the electric motors that will actuate Starship’s massive control surfaces – two large aft wings and two forward canards/fins. According to Musk, Starship’s “stability is controlled by (very) rapid movement of rear & fwd fins during entry & landing”, meaning that the spacecraft will need to constantly tweak its control surfaces to remain in stable flight.
By far the biggest challenge SpaceX faces is ensuring that Starship can survive numerous orbital-velocity reentries with little to no wear and tear, a necessity for Starship to be cost-effective. In Low Earth Orbit (LEO), Starship will be traveling no less than 7.8 km/s (Mach 23, 17,500 mph) at the start of atmospheric reentry. In simple terms, the process of slowing from orbital velocity to landing on Earth involves turning the vast majority of that kinetic energy into heat. As Musk noted yesterday, this reality is just shy of unavoidable but there is some flexibility in terms of how quickly one wants to convert that energy into heat.
The fastest route to Earth would involve diving straight into the atmosphere, dramatically increasing peak heating on a spacecraft’s surface to the point that extremely exotic heat shields and thermal protections systems become an absolute necessity. SpaceX wants to find a middle ground with Starship in which the spacecraft uses its aerodynamic control surfaces and body to generate lift, slowly and carefully lowering itself into Earth’s atmosphere over a period of 15+ minutes. Musk notes that this dramatically lessens peak heating at the cost of increasing the overall amount of energy Starship has to dissipate, a bit like cooking something in the oven at 300 degrees for 30 minutes instead of 600 degrees for 10 minutes.
To an extent, Starship’s reentry profile is actually quite similar to NASA’s now-retired Space Shuttle, which took approximately 30 minutes to go from its reentry burn to touchdown. Per the above infographic, it looks like Starship will take approximately 20 minutes from orbit to touchdown, owing to a dramatically different approach once it reaches slower speeds. Originally described by Musk in September 2018 and again in recent weeks, Starship will essentially stall itself until its forward velocity is nearly zero, after which the giant spacecraft will fall belly-down towards the Earth, using its wings and fins to maneuver like a skydiver. The Space Shuttle landed on a runway like a (cement-encased) glider.
This unusual approach allows SpaceX to sidestep the need for huge wings, preventing Starship from wasting far more mass on aerodynamic surfaces it will rarely need. The Space Shuttle is famous for its massive, tile-covered delta wing and the leading-edge shielding that partially contributed to the Columbia disaster. However, it’s a little-known fact that the wing’s size and shape were almost entirely attributable to US Air Force demands for cross-range performance, meaning that the military wanted Shuttles to be able to travel 1000+ miles during reentry and flight. This dramatically constrained the Shuttle’s design and was never once used for its intended purpose.
SpaceX thankfully doesn’t have its own “US Air Force” stand-in making highly consequential demands (aside from Elon Musk ?). Instead, Starship will continue the SpaceX tradition of vertical landing, falling straight down – a bit like a skydiver (or a brick) – on its belly and flipping itself over with fins and thrusters for a propulsive vertical landing. In this way, Starship doesn’t have to be a brick forced to fly, like the Shuttle was – it just needs to be able to stably fall and quickly flip itself from a horizontal to vertical orientation.
Additionally, Starship is built almost entirely out of steel, whereas the Shuttle relied on an aluminum alloy and needed thermal protection over every square inch of its hull. Steel melts at nearly twice the temperature of the Shuttle’s alloy, meaning that Starship will (hopefully) be able to get away with nothing more than ceramic tiles on its windward half, saving mass, money, and time. Once Starship completes its first 20 km (12.5 mi) flight test(s), currently scheduled no earlier than mid-October, SpaceX will likely turn its focus on verifying Starship’s performance at hypersonic speeds, ultimately culminating in its first orbital-velocity reentries.
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A Tesla Semi caught fire in Hayward, California, which caused both directions of traffic to shut down for hours before being completely reopened early on Wednesday, the California Highway Patrol said.
The fire occurred just after 5:30 local time in Hayward on Tuesday, as the Semi caught fire in the southbound lanes of I-880 before CHP officials made the decision to shut down both lanes of traffic due to potential risks from hazardous chemical smoke.
There were no injuries reported.
🚨 A Tesla Semi reportedly caught fire, with California Highway Patrol confirming. The Semi was on I-880 SB
An estimated 5,000 to 7,000 semi-truck and large commercial vehicle fires occur on U.S. roadways every year
— TESLARATI (@Teslarati) October 28, 2026
The cause of the fire is currently unknown, as neither Tesla nor the CHP have not determined a cause.
However, some images taken before the Semi was completely destroyed by the fire seem to indicate this might have been an older unit, as it appears to be one of the designs that Tesla shipped as part of its pilot program, before revising it and starting mass production just a month ago.
@Tslachan From on of the videos looks like it’s an old Semi (not the refresh version that recently started production) https://t.co/KzwmR2kXow
— Area Under The Curve 🎗️ (@AreaUnderCurve) October 28, 2026
At the time of publication, CHP had not returned our request for a comment for additional details, including the Semi involved and any potential collaboration on an investigation between the CHP and Tesla. We will update this story when we hear back from them.
The southbound lanes were reopened at 3:30 a.m. on Wednesday, with the northbound lanes opening last night a few hours after the fire began. The CHP did state that the lithium batteries were “incredibly difficult to extinguish,” according to NBC Bay Area.
The truck’s driver said that the Semi caught fire, but he did not have an explanation.
An estimated 5,000 to 7,000 semi-truck and large commercial vehicle fires occur on U.S. roadways every year.
Tesla’s launch of the “Emergency Drive Away” function a few months back offered owners a safe option to evacuate an area if they were in reasonable danger. The function finally got its first use in the real world, but it appears it was by mistake.
A video shared by u/Joshalander in the r/TeslaLounge subreddit recorded the instance from his vehicle and said the incident took place in Austin this past weekend during the city’s F1 Race.
“Was charging around 6 AM this past Sunday in Austin before heading to the F1 race and heard a pop. Looked over and saw the new emergency drive-away feature in action. Genuinely felt bad for the dude when he got out and realized what happened, since he looked exhausted and only seemed to half-read the prompts.”
🚨 Here’s the first look at Tesla’s Emergency Drive Away function in action:
Apparently this driver accidentally enabled it and drove forward; you can see the Supercharger pull with the car.
Tesla said previously this would cost up to $25k if not used properly. https://t.co/B4qQRrsO6B
— TESLARATI (@Teslarati) October 28, 2026
Emergency Drive Away unlatches the Supercharger connector from the vehicle, but still causes damage to both the car and the Supercharger. Tesla has said that it will cost up to $25,000 in repairs to have everything fixed back to normal.
Additionally, the company said that if it were not used in an emergency situation, the driver of the vehicle who activated the Emergency Drive Away feature would be responsible for all repair costs.
Tesla constitutes the following situations as reasonable justifications for activating the feature:
- You face an immediate threat to your life or personal safety.
- You must leave the area immediately.
- Exiting the vehicle is unsafe.
- Unplugging the charge connector would unreasonably delay your departure or expose you to a risk to your personal safety.
After using the feature, Tesla requires the driver to schedule Service so the car can be inspected.
News
Tesla’s Cybercab battery design could make robotaxis even cheaper
Tesla built the Cybercab’s battery pack with spare room for a future switch to LFP.
Tesla built the Cybercab’s battery pack with empty space inside it on purpose, and the reason points to a cheaper robotaxi down the road.
Robert Sumpf, Tesla’s director of mechanical design engineering for battery modules and packs, said the extra room beside and beneath the Cybercab’s modules was left there so the company can move to lithium iron phosphate cells later. “So, we protected this pack to go to an even lower energy dense chemistry as we scale and need to bring LFP into the platform,” Sumpf said in a Cybercab deep dive with Munro Live.
The Cybercab runs on Tesla’s own 4680 cells with a nickel chemistry today. LFP cells store less energy for their size, so a straight swap would cut range. The reserved space lets Tesla add more LFP cells to make up the difference. In return, Tesla would get cells that cost less, run cooler and survive more charge cycles. LFP became the most used EV battery chemistry in the world last year.
Not all of that room was planned for a chemistry change. Lars Moravy, Tesla’s Vice President of Vehicle Engineering, said part of it exists because “we didn’t need as many batteries as we thought we did.” Tesla told Sandy Munro in early 2025 that it was targeting a Cybercab pack under 50 kWh with close to 300 miles of range.
The pack also breaks from the structural design Tesla used in some Model Y and Cybertruck builds. Instead of potting hundreds of cells into one block, the Cybercab uses four separate, individually sealed modules, so a bad module can be replaced without scrapping the whole pack. Sumpf was blunt about the older approach, giving the Model Y structural battery “a grade D” because it was hard to build and nearly impossible to repair. He estimated a fully structural pack gains about 10% more cell volume, but said “the issue is the service cost.”
That cost matters more for a car that rarely sits parked. Cybercab chief engineer Eric Earley said replacing an entire pack “before half a million miles is a killer on cost,” which is why remanufacturing and serviceability were built into the design from the start.
The same Munro Live tour produced Moravy’s admission that the Cybercab line at Giga Texas is now outpacing Robotaxi deployments, along with a look at the robotaxi’s unorthodox paint process. Tesla is aiming to deliver the first Cybercabs to outside customers by the end of 2026, though Elon Musk has said the vast majority will stay owned by Tesla and run as a transport service.
Sumpf did not give a date for an LFP version, name a cell supplier or say how a chemistry change would affect range. For now, the 4680 cars keep piling up: Texas DMV records from Tuesday list 544 Cybercabs authorized for Tesla’s Robotaxi fleet, more than the 507 Model Ys on the same roster for the first time.
Tesla Semi catches fire in California: what we know
Tesla’s ‘Emergency Drive Away’ function gets its first use in the real world
