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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.

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.

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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.

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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Tesla Model Y gets fresh configuration with three highly requested features

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Credit: Tesla

Tesla has launched a new Model Y configuration in the “Premium” trim, and it comes with three highly requested features that have launched in markets outside of the U.S. and in other trims.

Tesla announced on Monday night that it has officially launched the Model Y Premium in a seven-seat configuration, which also comes standard with a 16″ touchscreen and black headliner, both of which are featured in the Model Y Performance trim.

The seven-seat configuration is highly requested by consumers and helps fill out the more spacious SUV offering that the lineup has missed outside of the Model X, which prices out many consumers. This new upgrade only costs $2,500 extra for all three features, bringing the cash price to $48,990.

The move to add the seven-seat configuration with the black headliner and additional screen size is a welcome addition, as many Tesla fans have asked the company to come out with an SUV with more seating capacity. Although it is not a full-size SUV, the additional seating will certainly attract some buyers with bigger families.

It appears the third row is slightly more spacious than the past iteration of the seven-seat Model Y, which was available in the previous design pre-Juniper:

 

Credit: Tesla

However, it definitely still appears to be pretty cramped in terms of legroom. It will definitely be a seating arrangement for smaller passengers, mostly reserved for children.

The other two upgrades are the black headliner, which was launched in other markets and in the Model Y Performance. Many owners have wanted this change, and Tesla listened, but is only offering it with the seven-seat configuration. It also has a larger 16″ touchscreen, also present in the Model Y Performance exclusively:

Credit: Tesla

It is a nice touch to add these highly requested features to the all-electric crossover, which was the best-selling vehicle in the world for the third consecutive year.

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Tesla expands its branded ‘For Business’ Superchargers

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Credit: Francis Energy

Tesla has expanded its branded ‘For Business’ Supercharger program that it launched last year, as yet another company is using the platform to attract EV owners to its business and utilize a unique advertising opportunity.

Francis Energy of Oklahoma is launching four Superchargers in Norman, where the University of Oklahoma is located. The Superchargers, which are fitted with branding for Francis Energy, will officially open tomorrow.

It will not be the final Supercharger location that Francis Energy plans to open, the company confirmed to EVWire.

Back in early September, Tesla launched the new “Supercharger for Business” program in an effort to give businesses the ability to offer EV charging at custom rates. It would give their businesses visibility and would also cater to employees or customers.

“Purchase and install Superchargers at your business,” Tesla wrote on a page on its website for the new program. “Superchargers are compatible with all electric vehicles, bringing EV drivers to your business by offering convenient, reliable charging.”

The first site opened in Land O’ Lakes, Florida, which is Northeast of Tampa, as a company called Suncoast launched the Superchargers for local EV owners.

Tesla launches its new branded Supercharger for Business with first active station

The program also does a great job at expanding infrastructure for EV owners, which is something that needs to be done to encourage more people to purchase Teslas and other electric cars.

Francis Energy operates at least 14 EV charging locations in Oklahoma, spanning from Durant to Oklahoma City and nearly everywhere in between. Filings from the company, listed by Supercharge.info, show the company’s plans to convert some of them to Tesla Superchargers, potentially utilizing the new Supercharger for Business program to advertise.

Moving forward, more companies will likely utilize Tesla’s Supercharger for Business program as it presents major advantages in a variety of ways, especially with advertising and creating a place for EV drivers to gain range in their cars.

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Tesla Cybercab ‘breakdown’ image likely is not what it seems

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Credit: TslaChan | X

Tesla Cybercab is perhaps the most highly-anticipated project that the company plans to roll out this year, and as it is undergoing its testing phase in pre-production currently, there are some things to work through with it.

Over the weekend, an image of the Cybercab being loaded onto a tow truck started circulating on the internet, and people began to speculate as to what the issue could be.

The Cybercab can clearly be seen with a Police Officer and perhaps the tow truck driver by its side, being loaded onto, or even potentially unloaded from, the truck.

However, it seems unlikely it was being offloaded, as its operation would get it to this point for testing to begin with.

It appears, at first glance, that it needs assistance getting back to wherever it came from; likely Gigafactory Texas or potentially a Bay Area facility.

The Cybercab was also spotted in Buffalo, New York, last week, potentially undergoing cold-weather testing, but it doesn’t appear that’s where this incident took place.

It is important to remember that the Cybercab is currently undergoing some rigorous testing scenarios, which include range tests and routine public road operation. These things help Tesla assess any potential issue the vehicle could run into after it starts routine production and heads to customers, or for the Robotaxi platform operation.

This is not a one-off issue, either. Tesla had some instances with the Semi where it was seen broken down on the side of a highway three years ago. The all-electric Semi has gone on to be successful in its early pilot program, as companies like Frito-Lay and PepsiCo. have had very positive remarks.

Tesla reveals its first Semi customer after launch

The Cybercab’s future is bright, and it is important to note that no vehicle model has ever gone its full life without a breakdown. It happens, it’s a car.

Nevertheless, it is important to note that there has been no official word on what happened with this particular Cybercab unit, but it is crucial to remember that this is the pre-production testing phase, and these things are more constructive than anything.

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