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SpaceX’s first high-altitude Starship gets ready to prove itself

SpaceX has begun installing functional aerodynamic control surfaces on a Starship prototype for the first time. (NASASpaceflight - bocachicagal)

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5 years ago

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SpaceX has begun outfitting its first high-altitude Starship prototype with the basis of functional aerodynamic flaps, potentially paving the way for the ship’s first crucial proof test(s) in the near future.

Unsurprisingly, the first real attempt to install the functional ‘flaps’ Starships will use to fall back to Earth and land has been (relatively) slow going. The tank and engine section of Starship serial number 8 (SN8) – the high-altitude prototype-to-be – was stacked to its full height around August 27th. Shorthand for curved steel sections meant to make Starships more aerodynamic and protect sensitive mechanisms, the first signs of functional ‘aerocovers’ arrived in Boca Chica a few days later on August 31st.

Aerocover ‘caps’ arrived in Boca Chica in mid-August. (NASASpaceflight – bocachicagal)
Long shrouds arrived in mid-September. (NASASpaceflight – bocachicagal)
A possible aerocover installation jig or flap frame. In the foreground, SpaceX already has several pairs of flaps on hand whenever SN8 is ready for them. (NASASpaceflight – bocachicagal)

A much longer aerocover appeared on September 11th and SpaceX appeared to begin installing it on Starship SN8 around September 14th, temporarily tack-welding it to the rocket’s hull. SpaceX may be using a sort of alignment jig (bottom photo above) to ensure that the extremely thin and flexible steel covers are easily installed in a uniform fashion where they’re supposed to be.

If not, the LEGO-esque structure could also be a rudimentary frame for Starship’s aft flaps – heavy and inefficient but extremely cheap and easy to build and tweak. Most of that work is being done inside SpaceX’s Starship assembly building, largely hidden from sight from public perspectives, so it’s hard to say anything with certainty until SN8 rolls out for the first time.

A closer view of the Starship SN8’s first aerocover. (NASASpaceflight – bocachicagal)
Starship SN7.1 is still awaiting its destructive end. (NASASpaceflight – bocachicagal)
SpaceX is already preparing for what comes after SN7.1, however. (NASASpaceflight – bocachicagal)

When that milestone will come is unclear, likely to the extent that even SpaceX isn’t sure. Currently, it’s unknown if SpaceX will fully outfit Starship SN8 with a nosecone and all four flaps before putting the prototype through its first proof tests – possibly up to and including the first static fire test with three Raptor engines. Starship SN8 is the first full-size prototype built out of a new steel alloy and while that alloy is currently being tested to its limits by test tank SN7.1, proving SN8’s integrity first would save a lot of time and effort in the event that SpaceX has more to learn about the limits of 304L steel and the ship fails during basic testing.

If SpaceX chooses to perform a cryogenic proof test prior to fully installing flaps and a nosecone, Starship SN8 could feasibly roll to the launch pad well before the end of the month. In fact, SpaceX moved a hydraulic ram used to simulate Raptor thrust back to the main test stand – where SN8 will likely undergo its first tests – on September 19th. Typically, that ram has been installed just days before a Starship is transported from factory to launch pad.

In the event that SpaceX chooses to perform a cryo proof test and/or static fire prior to fully integrating Starship SN8, the ship could likely be easily moved back to the factory to have its nosecone and flaps installed. Either way, chances are good that SN8 will be ready to head to the launch pad for its first test campaign within the next two weeks.

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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’s Robotaxi expansion wasn’t a joke, it was a warning to competitors

Tesla might have made a joke with its first Robotaxi service area expansion, but it was truly a serious warning to its competitors.

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7 hours ago

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July 14, 2025

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Tesla’s Robotaxi expansion occurred for the first time on Monday, and while the shape of its new service area might be “cocky,” it surely is not a joke. It’s a warning to competitors.

Robotaxi skeptics and Tesla opponents are sitting around throwing hate toward the company’s expansion appearance. Some called it “unserious,” and others say it’s “immature.” The reality is that it has a real meaning that goes much further than the company’s lighthearted and comical attitude toward things.

For context, Tesla has routinely used the number 69 as a way to price things it sells. 420 is another, an ode to cannabis culture. A few years back, it actually priced its Model S flagship sedan at $69,420. The first rides of the Robotaxi fleet were priced at $4.20. They are now being increased to $6.90.

Some call it childish. Others call it fun. The truth is, nobody is doing it this way.

Tesla updates Robotaxi app with several big changes, including wider service area

But today’s expansion of the Robotaxi service area in Austin is different. Tesla did not expand its shape to different neighborhoods or areas of the City of Austin. It did not expand it by broadening the rectangle that was initially available. Instead, it chose a different strategy, simply because it could:

Tesla could have done anything. It could have expanded in any direction, in any way, but it chose this simply because it has gotten Robotaxi to the point that it can broaden its service area in any direction. It chose this shape because it could.

Other companies might not have the same ability. Of course, many companies probably would not do this even if it could, simply because of the optics. Tesla doesn’t have those concerns; it has been open about its ability to be funny, and yes, immature, at times.

But in reality, it was a stark warning to competitors. “We can go anywhere in Austin, at any time, and we’re confident enough to make a joke about it.”

Tesla’s Robotaxi geofence in Austin grows, and its shape is hard to ignore

As Tesla is already aiming to expand to new states and high-population areas, and with applications filed in Arizona and California, Robotaxi will be in new regions in the coming weeks or months.

For now, it remains in Austin, and Tesla is sending a message to other companies that it is ready to go in any direction. The driverless Robotaxi fleet, bolstered by billions of miles of data, is ready to roam without anyone at the wheel.

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Tesla Robotaxi has already surpassed Waymo in this key metric

Tesla Robotaxi has already overtaken Waymo in Austin in one key metric, but there’s still more work to do.

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12 hours ago

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July 14, 2025

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Credit: @HanChulYong/X

Tesla Robotaxi has already surpassed Waymo in one extremely important key metric: size of service area.

Tesla just expanded its service area in Austin on Monday morning, pushing the boundaries of its Robotaxi fleet in an interesting fashion with new capabilities to the north. Yes, we know what it looks like:

The expansion doubled Tesla Robotaxi’s potential travel locations, which now include the University of Texas at Austin, a school with over 53,000 students.

The doubling of the service area by Tesla has already made its travel area larger than Waymo’s, which launched driverless rides in October 2024. It became available to the public in March 2025.

According to Grok, the AI agent on X, Tesla Robotaxi’s current service area spans 42 square miles, which is five square miles larger than Waymo’s service area of 37 square miles.

The service area is one of the most important metrics in determining how much progress a self-driving ride-hailing service is making. Safety is the priority of any company operating a ride-hailing network, especially ones that are making it a point to use autonomy to deploy it.

However, these companies are essentially racing for a larger piece of the city or cities they are in. Waymo has expanded to several different regions around the United States, including Arizona and Los Angeles.

Tesla is attempting to do the same in the coming months as it has already filed paperwork in both California and Arizona to deploy its Robotaxi fleet in states across the U.S.

As the platform continues to show more prowess and accuracy in its operation, Tesla will begin to expand to new areas, eventually aiming for a global rollout of its self-driving service.

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Tesla Megapacks arrive for massive battery replacing coal plant

Tesla Megapacks have started arriving on-site to the Stanwell Battery Project, just as Queensland prepares to wind down the Stanwell coal plant.

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13 hours ago

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July 14, 2025

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Tesla-megapack-pilot-project-willowbrook-mall
Credit: Tesla

The first of over 300 Tesla Megapacks have arrived to the site of a massive battery energy storage system (BESS) being built in Australia, dubbed the Stanwell Battery Project after a coal plant it’s set to replace.

In a press release last week, the Stanwell Battery Project announced that the first Tesla Megapack 2XL units had arrived to the site, which is located outside of Rockhampton in Queensland, Australia. The project will eventually feature 324 Megapack units, set to arrive in the coming months, in order to support the 300MW/1,200MWh battery project.

“The Stanwell Battery is part of the diversification of our portfolio, to include cleaner and more flexible energy solutions,” said Angie Zahra, Stanwell Central Generation General Manager. “It is just one part of the 800 MW of battery energy storage capacity we have in our pipeline.

“Capable of discharging 300 MW of energy for up to four hours (1,200 MWh), our mega battery will be one of the largest in Queensland.”

Credit: Stanwell

READ MORE ON TESLA MEGAPACKS: Tesla Lathrop Megafactory celebrates massive Megapack battery milestone

The state is working with government-owned company Yurika to facilitate construction, and the process is expected to create roughly 80 jobs. The project is expected to come fully online in May 2027, with initial commissioning of the Megapacks aiming for November 2025.

The Stanwell Battery is set to replace the nearby Stanwell coal generation plant, which the government is planning to wind down starting in 2026 as part of efforts to reach an 80 percent renewable energy generation ratio by 2035. Meanwhile, the government is also set to begin winding down the Tarong and Callide coal plants, while several other Megapack projects are being built or coming online. o ya

Tesla currently has two Megapack production facilities, located in Lathrop, California, in the U.S. and another that came online earlier this year in Shanghai, China. The Shanghai Megafactory shipped its first units to Australia in March, while both factories are expected to be capable of producing 10,000 Megapack units per year upon reaching volume production.

xAI receives more Tesla Megapacks for Colossus 2

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