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SpaceX CEO Elon Musk says major Starship engine bug is fixed as Raptor testing continues

Starhopper awaits its first truly flightworthy Raptor as CEO Elon Musk says SpaceX may have solved the technical bug delaying hop tests. (NASASpaceflight - bocachicagal, SpaceX)

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SpaceX CEO Elon Musk has revealed the latest official photo of the company’s Raptor engine in action and indicated that a major technical issue with vibration appears to have been solved, hopefully paving the way for Starhopper’s first untethered flights.

Partly due to Musk’s own involvement in the program, SpaceX’s propulsion development team have struggled to get any single Raptor engine to survive more than 50-100 seconds of cumulative test fires. According to information from sources familiar with the program, Musk has enforced an exceptionally hardware-rich development program for the first full-scale Raptor engines to such an extent that several have been destroyed so completely that they could barely be used to inform design optimization work. Although likely more strenuous and inefficient than it needed to be, the exceptionally hardware-rich test program appears to have begun to show fruit, with the sixth engine built (SN06) passing its first tests without exhibiting signs of a problem that has plagued most of the five Raptors that came before it.

Resonance: not even once

In his tweet, Musk cryptically noted that a “600 Hz Raptor vibration problem” appears to have been fixed as of SN06’s first few static fire tests since arriving in McGregor, Texas. More likely than not, the self-taught SpaceX executive is referring to the hell that is mechanical resonance in complex machines and structures. Shown below, the Tacoma Narrows Bridge’s 1940 collapse – quite possibly the single most famous civil engineering failure of all time – is an iconic example of the unintuitive power of resonance in complex systems.

An excellent overview of the challenges and fairly young history of mechanical resonance in modern engineering.

When it was inaugurated, the first Tacoma Narrows Bridge was one of the longest suspension bridges ever built and implemented new techniques and technologies that had never been tried at such a large scale. As Grady (Practical Engineer) aptly notes, mechanical resonance – in this case, triggered by consistent winds running through the Puget Sound – simply wasn’t something that period engineers knew they had to worry about. When rapidly pushing the envelope of engineering and construction, the chances of discovering entirely novel failure modes also increases – it’s simply one of the costs of extreme innovation.

The first finalized Raptor engine (SN01) completed a successful static fire debut on the evening of February 3rd. (SpaceX)
Just five days after its first ignition, SpaceX successfully tested Raptor SN01 at more than twice the thrust of Merlin 1D. (SpaceX)
The latest official photo of Raptor testing in McGregor. This engine is likely SN06, the sixth Raptor produced in 2019. (SpaceX/Elon Musk)

Luckily for SpaceX, the company doesn’t have to clash with the immense challenge of testing something as large, complex, and expensive as a suspension bridge. Raptor, Starship, and Super Heavy need not necessarily be perfect on SpaceX’s first try, whereas civil bridges must essentially be flawless on the first try, despite being one of a kind. This is why SpaceX has been chewing through an average of one Raptor engine per month since February 2019 – by testing engines to destruction and aggressively comparing engineering expectations with observed behavior and post-test hardware conditions, rapid progress can (theoretically) be made.

Instead of spending another year or more analyzing models and testing subscale engines and components, SpaceX dove into integrated testing of a sort of minimum-viable-product Raptor design, accepting that the path to a flightworthy, finalized design would likely be paved with one or several dozen destroyed engines. According to Musk, the biggest pressing design deficiency involved a mode of mechanical resonance that may or may not have been predicted over the course of the design process. Dealing with unprecedented conditions, it’s not particularly surprising that some sort of new resonance mode was discovered in Raptor.

For the time being, SpaceX continues to work around the clock to build its first two orbital Starship prototypes (one in Texas, one in Florida), while also outfitting Starhopper and completing any possible engine-less tests in anticipation of the first flightworthy Raptor’s arrival. If Musk’s early analysis proves correct and Raptor SN06 makes it through lengthier static fire tests unscathed over the next week or so, the engine could potentially be delivered to Boca Chica as early as mid-July.

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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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Tesla teases new market entrance with confusing and cryptic message

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(Credit: Tesla)

Tesla teased its entrance into a new market with a confusing and what appeared to be cryptic message on the social media platform X.

The company has been teasing its entrance into several markets, including Africa, which would be a first, and South America, where it only operates in Chile.

In September, Tesla started creating active job postings for the Colombian market, hinting it would expand its presence in South America and launch in a new country for the first time in two years.

Tesla job postings seem to show next surprise market entry

The jobs were related to various roles, including Associate Sales Manager, Advisors in Sales and Delivery, and Service Technicians. These are all roles that would indicate Tesla is planning to launch a wide-scale effort to sell, manage, and repair vehicles in the market.

Last night, Tesla posted its latest hint, a cryptic video that seems to show the outline of Colombia, teasing its closer than ever to market entry:

This would be the next expansion into a continent where it does not have much of a presence for Tesla. Currently, there are only two Supercharger locations on the entire continent, and they’re both in Chile.

Tesla will obviously need to expand upon this crucial part of the ownership experience to enable a more confident consumer base in South America as a whole. However, it is not impossible, as many other EV charging infrastructures are available, and home charging is always a suitable option for those who have access to it.

Surprisingly, Tesla seems to be more concerned about these middle-market countries as opposed to the larger markets in South America, but that could be by design.

If Tesla were to launch in Brazil initially, it may not be able to handle the uptick in demand, and infrastructure expansion could be more difficult. Brazil may be on its list in the upcoming years, but not as of right now.

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Tesla expands crucial Supercharging feature for easier access

It is a useful tool, especially during hours of congestion. However, it has not been super effective for those who drive non-Tesla EVs, as other OEMs use UI platforms like Google’s Android Auto or Apple’s iOS.

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tesla supercharger
Credit: Tesla

Tesla has expanded a crucial Supercharging feature that helps owners identify stall availability at nearby locations.

Tesla said on Tuesday night that its “Live Availability” feature, which shows EV owners how many stalls are available at a Supercharger station, to Google Maps, a third-party app:

Already offering it in its own vehicles, the Live Availability feature that Teslas have is a helpful feature that helps you choose an appropriate station with plugs that are immediately available.

A number on an icon where the Supercharger is located lets EV drivers know how many stalls are available.

It is a useful tool, especially during hours of congestion. However, it has not been super effective for those who drive non-Tesla EVs, as other OEMs use UI platforms like Google’s Android Auto or Apple’s iOS.

Essentially, when those drivers needed to charge at a Supercharger that enables non-Tesla EVs to plug in, there was a bit more of a gamble. There was no guarantee that a plug would be available, and with no way to see how many are open, it was a risk.

Tesla adding this feature allows people to have a more convenient and easier-to-use experience if they are in a non-Tesla EV. With the already expansive Supercharger Network being available to so many EV owners, there is more congestion than ever.

This new feature makes the entire experience better for all owners, especially as there is more transparency regarding the availability of plugs at Supercharger stalls.

It will be interesting to see if Tesla is able to expand on this new move, as Apple Maps compatibility is an obvious goal of the company’s in the future, we could imagine. In fact, this is one of the first times an Android Auto feature is available to those owners before it became an option for iOS users.

Apple owners tend to get priority with new features within the Tesla App itself.

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Elon Musk’s Boring Co goes extra hard in Nashville with first rock-crushing TBM

The Boring Company’s machine for the project is now in final testing.

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Credit: The Boring Company/X

The Boring Company is gearing up to tackle one of its toughest projects yet, a new tunnel system beneath Nashville’s notoriously tough limestone terrain. Unlike the soft-soil conditions of Las Vegas and Austin, the Music City Loop will require a “hard-rock” boring machine capable of drilling through dense, erosion-resistant bedrock. 

The Boring Company’s machine for the project is now in final testing.

A boring hard-rock tunneling machine

The Boring Company revealed on X that its new hard-rock TBM can generate up to 4 million pounds of grip force and 1.5 million pounds of maximum thrust load. It also features a 15-filter dust removal system designed to keep operations clean and efficient during excavation even in places where hard rock is present.

Previous Boring Co. projects, including its Loop tunnels in Las Vegas, Austin, and Bastrop, were dug primarily through soft soils. Nashville’s geology, however, poses a different challenge. Boring Company CEO and President Steve Davis mentioned this challenge during the project’s announcement in late July.

“It’s a tough place to tunnel, Nashville. If we were optimizing for the easiest places to tunnel, it would not be here. You have extremely hard rock, like way harder than it should be. It’s an engineering problem that’s fairly easy and straightforward to solve,” Davis said.

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Nashville’s limestone terrain

Experts have stated that the city’s subsurface conditions make it one of the more complex tunneling environments in the U.S. The Outer Nashville Basin is composed of cherty Mississippian-age limestone, a strong yet soluble rock that can dissolve over time, creating underground voids and caves, as noted in a report from The Tennessean.

Jakob Walter, the founder and principal engineer of Haushepherd, shared his thoughts on these challenges. “Limestone is generally a stable sedimentary bedrock material with strength parameters that are favorable for tunneling. Limestone is however fairly soluble when compared to other rack materials, and can dissolve over long periods of time when exposed to water. 

“Unexpected encounters with these features while tunneling can result in significant construction delays and potential instability of the excavation. In urban locations, structures at the ground surface should also be constantly monitored with robotic total stations or similar surveying equipment to identify any early signs of movement or distress,” he said.

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