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SpaceX's Elon Musk works through holidays on Starship's "most difficult part"

SpaceX CEO Elon Musk is working with the company's Boca Chica team to get Starship's "most difficult part" ready for flight. (NASASpaceflight - bocachicagal)

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SpaceX CEO Elon Musk says he has been working through the holidays at the company’s Boca Chica facilities to get Starship’s “most difficult part” ready for the next-generation spacecraft’s next prototype and flight tests.

Known as tank domes or bulkheads, Musk says that the hardware is the most difficult part of building and assembly Starship’s primary structure, referring to the steel engine section, tanks, and pointed nose that comprise most of the spaceship’s body. Starship’s primary structure must stand up to the rigors of all aspects of flight, including highly-pressurized propellant tanks, extreme G-forces during launches, orbital reentry, and more.

It was never officially determined whether the failure was intentional or not but during the first Starship prototype’s (Mk1) last test campaign, the vehicle experience an overpressure event while being filled with liquid oxygen or nitrogen. Localized to the weld connecting the upper tank dome to Starship’s cylindrical tank section, the dome essentially sheared off at the weld and launched hundreds of feet into the air, sending a shockwave through the vehicle that crumpled many of its steel structures as if they were aluminum foil.

It’s likely that Starship Mk1’s failure was an intentional overpressure event, meaning that SpaceX may have purposely pressed the vehicle’s tanks beyond their design limits to determine how structurally sound they were. What is less clear is whether the rocket burst before or after reaching its theoretical design limit.

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For reference, SpaceX’s Falcon 9 rocket operates with its fuel and oxygen tanks pressurized to about 50 psi (3.5 atm) with localized pressures likely doubling or tripling near the bottom of both tanks during the first minute or two of launch. Some amateur back-of-the-envelope calculations from videos of Starship Mk1’s burst event suggest that it was pressurized to at least 60-75 psi (4-5 atm) at its upper tank dome, meaning that the pressure on its two lower domes and tank walls would have been even higher. If correct, those unofficial figures mean that Mk1 actually performed quite well considering the ramshackle facilities and unprecedentedly spartan methods used to fabricate and assemble it.

As such, Musk likely considers Starship’s tank domes the “most difficult part of [its] primary structure” in large part because of how difficult it is to make giant propellant tank domes simultaneously light and strong. Musk has previously implied that Starship Mk1 was more 200 tons (450,000 lb) empty while the ultimate goal for the spacecraft’s empty weight is closer to 120 tons, and a large portion of that weight savings will likely have to come from making its tank domes as light as possible.

In line with that educated speculation, the last month or so of SpaceX’s Starship work in Boca Chica, Texas has been marked by a distinct focus on building tank domes. In fact, Musk himself tweeted that he had worked all night with SpaceX engineers in Boca Chica in a bid to get dome production ready for Starship’s Mk3 prototype, the first Super Heavy hardware, and many more rockets to come.

Prior to Musk’s tweet, a Starship tank dome was actually shipped all the way from Florida to Texas and arrived earlier this month. Meanwhile, technicians have been briskly building up an additional dome using what appears to be a different method of integration involving new parts. SpaceX is currently attempting to weld Starship’s tank domes together from several dozen pre-formed sheets of stainless steel.

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The sheets of steel assembled into the dome Musk showed on December 27th likely arrived in Boca Chica on December 13th, implying that SpaceX has managed to complete the majority of the first dome prototype – using a new process – in barely two weeks.

New sections of a tank dome arrived on December 13th. (NASASpaceflight – bocachicagal)
Technicians lifted the dome Musk was working on on December 28th, implying that it is more or less structurally complete. (NASASpaceflight – bocachicagal)
Hours after lifting the newest dome, SpaceX began assembling the next one. (NASASpaceflight – bocachicagal)
Starship’s third Boca Chica tank dome was spotted in-work on December 28th. (NASASpaceflight – bocachicagal)

After SpaceX lifted the partially-completed dome off one of its custom assembly jigs, workers almost instantly began staging new sections of steel, beginning the process of integrating yet another tank dome – now likely the fourth on-site in Boca Chica. Meanwhile, at a nearby section of SpaceX’s Boca Chica production facilities, yet another dome was visible on the 28th. In short, SpaceX should soon have more than enough tank domes to complete the next Starship prototype – said to be a significantly improved and refined design compared to Mk1.

Known as Starship Mk3 (or Starship SN01), Musk says that the rocket – currently just a miscellaneous collection of separate parts – could (“hopefully”) be ready for its first flight as soon as February or March 2020.

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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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Brazil Supreme Court orders Elon Musk and X investigation closed

The decision was issued by Supreme Court Justice Alexandre de Moraes following a recommendation from Brazil’s Prosecutor-General Paulo Gonet.

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Gage Skidmore, CC BY-SA 4.0 , via Wikimedia Commons

Brazil’s Supreme Federal Court has ordered the closure of an investigation involving Elon Musk and social media platform X. The inquiry had been pending for about two years and examined whether the platform was used to coordinate attacks against members of the judiciary.

The decision was issued by Supreme Court Justice Alexandre de Moraes following a recommendation from Brazil’s Prosecutor-General Paulo Gonet.

According to a report from Agencia Brasil, the investigation conducted by the Federal Police did not find evidence that X deliberately attempted to attack the judiciary or circumvent court orders.

Prosecutor-General Paulo Gonet concluded that the irregularities identified during the probe did not indicate fraudulent intent.

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Justice Moraes accepted the prosecutor’s recommendation and ruled that the investigation should be closed. Under the ruling, the case will remain closed unless new evidence emerges.

The inquiry stemmed from concerns that content on X may have enabled online attacks against Supreme Court justices or violated rulings requiring the suspension of certain accounts under investigation.

Justice Moraes had previously taken several enforcement actions related to the platform during the broader dispute involving social media regulation in Brazil.

These included ordering a nationwide block of the platform, freezing Starlink accounts, and imposing fines on X totaling about $5.2 million. Authorities also froze financial assets linked to X and SpaceX through Starlink to collect unpaid penalties and seized roughly $3.3 million from the companies’ accounts.

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Moraes also imposed daily fines of up to R$5 million, about $920,000, for alleged evasion of the X ban and established penalties of R$50,000 per day for VPN users who attempted to bypass the restriction.

Brazil remains an important market for X, with roughly 17 million users, making it one of the platform’s larger user bases globally.

The country is also a major market for Starlink, SpaceX’s satellite internet service, which has surpassed one million subscribers in Brazil.

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FCC chair criticizes Amazon over opposition to SpaceX satellite plan

Carr made the remarks in a post on social media platform X.

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Credit: @SecWar/X

U.S. Federal Communications Commission (FCC) Chairman Brendan Carr criticized Amazon after the company opposed SpaceX’s proposal to launch a large satellite constellation that could function as an orbital data center network.

Carr made the remarks in a post on social media platform X.

Amazon recently urged the FCC to reject SpaceX’s application to deploy a constellation of up to 1 million low Earth orbit satellites that could serve as artificial intelligence data centers in space.

The company described the proposal as a “lofty ambition rather than a real plan,” arguing that SpaceX had not provided sufficient details about how the system would operate.

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Carr responded by pointing to Amazon’s own satellite deployment progress.

“Amazon should focus on the fact that it will fall roughly 1,000 satellites short of meeting its upcoming deployment milestone, rather than spending their time and resources filing petitions against companies that are putting thousands of satellites in orbit,” Carr wrote on X.

Amazon has declined to comment on the statement.

Amazon has been working to deploy its Project Kuiper satellite network, which is intended to compete with SpaceX’s Starlink service. The company has invested more than $10 billion in the program and has launched more than 200 satellites since April of last year.

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Amazon has also asked the FCC for a 24-month extension, until July 2028, to meet a requirement to deploy roughly 1,600 satellites by July 2026, as noted in a CNBC report.

SpaceX’s Starlink network currently has nearly 10,000 satellites in orbit and serves roughly 10 million customers. The FCC has also authorized SpaceX to deploy 7,500 additional satellites as the company continues expanding its global satellite internet network.

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Energy

Tesla Energy gains UK license to sell electricity to homes and businesses

The license was granted to Tesla Energy Ventures Ltd. by UK energy regulator Ofgem after a seven-month review process.

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Credit: Tesla Energy/X

Tesla Energy has received a license to supply electricity in the United Kingdom, opening the door for the company to serve homes and businesses in the country.

The license was granted to Tesla Energy Ventures Ltd. by UK energy regulator Ofgem after a seven-month review process.

According to Ofgem, the license took effect at 6 p.m. local time on Wednesday and applies to Great Britain.

The approval allows Tesla’s energy business to sell electricity directly to customers in the region, as noted in a Bloomberg News report.

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Tesla has already expanded similar services in the United States. In Texas, the company offers electricity plans that allow Tesla owners to charge their vehicles at a lower cost while also feeding excess electricity back into the grid.

Tesla already has a sizable presence in the UK market. According to price comparison website U-switch, there are more than 250,000 Tesla electric vehicles in the country and thousands of Tesla home energy storage systems.

Ofgem also noted that Tesla Motors Ltd., a separate entity incorporated in England and Wales, received an electricity generation license in June 2020.

The new UK license arrives as Tesla continues expanding its global energy business.

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Last year, Tesla Energy retained the top position in the global battery energy storage system (BESS) integrator market for the second consecutive year. According to Wood Mackenzie’s latest rankings, Tesla held about 15% of global market share in 2024.

The company also maintained a dominant position in North America, where it captured roughly 39% market share in the region.

At the same time, competition in the energy storage sector is increasing. Chinese companies such as Sungrow have been expanding their presence globally, particularly in Europe.

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