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SpaceX’s first Starship booster a step closer as custom parts arrive

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5 years ago

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While SpaceX remains focused on Starship flight testing as the dust settles from SN8’s launch debut, the company continues to make slow but steady progress building the first Super Heavy booster prototype.

For the most part, SpaceX has learned from trial and error and developed a decent stainless steel rocket manufacturing process by building a dozen Starship prototypes over the last ~12 months, ranging from a lone nosecone tip to stout test tanks and Starship SN8, which launched to 12.5 km (~7.8 mi) earlier this month. Practically identical below the nose, Super Heavy directly benefits from that maturity and is more or less an extended Starship tank section with more engines and bigger legs.

In many ways, Super Heavy can be much simpler than Starship, as a suborbital booster has no need for header tanks, flaps, or a nosecone, and can be much stronger and heavier in all aspects. However, carrying three or more times as propellant as Starship (and carrying Starship itself), Super Heavy also needs to be stronger. All those changes – requiring new design work and new fabrication – take time. In a great sign that most of that work is complete, some of that custom hardware needed to strengthen and power Super Heavy has begun to arrive over the last several weeks.

Known as BN1 (booster number 1), SpaceX began stacking the first Super Heavy on November 8th. (NASASpaceflight – bocachicagal)

SpaceX began stacking the first Super Heavy booster (BN1) on November 8th and appears to have more or less paused integration operations after joining eight rings. Production continued apace, however, and no less than five ring sections destined for Super Heavy appeared over the next several weeks. Why assembly slowed down is unclear but it’s reasonable to assume that SpaceX was trying to keep its focus primarily on Starship SN8’s launch debut and the preparation of several other full-scale ships, where early work on Super Heavy could ultimately be for naught if Starship flight tests uncover major design flaws.

Regardless of the reason, BN1 remains eight rings (14.5m/48ft) tall as of December 14th, representing one-fifth of Super Heavy’s full 70-meter (~230 ft) height.

Assuming they aren’t waiting to be scrapped, at least 20-24 of the 31-32 Super Heavy BN1 rings remaining are ready and waiting for dome integration and stacking. (NASASpaceflight – bocachicagal)

On December 17th, one of the parts unique to Super Heavy unexpectedly appeared in SpaceX’s South Texas shipyard, labeled “B1 FWD PIPE DOME”. The dome was quickly sleeved with a stack of three steel rings with labels confirming that the assembly was Super Heavy BN1’s common tank dome – “common” because it’s shared by both booster propellant tanks. The new dome is unique to all previous Starship domes, featuring a smaller, more reinforced cutout – likely because Super Heavy doesn’t need header tanks.

It also appears to borrow from Starship’s forward dome design, using the same rougher steel normally used to cap off Starship methane tanks.

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BN1’s sleeved common dome. (NASASpaceflight – bocachicagal)
A normal Starship forward dome. (NASASpaceflight – bocachicagal)

Unlike Starship common domes, which place a spherical methane header tank at the bottom, Super Heavy’s common dome will have a transfer tube welded directly to its nozzle-like opening. As it turns out, what could be the first Super Heavy methane transfer tube was delivered to Boca Chica late last month.

Unlike Starship transfer tubes, the new plumbing appeared to have a much wider diameter and was delivered in four sections, meshing well with the fact that Super Heavy tanks are roughly twice as tall as Starship’s. Able to support as many as 28 Raptors compared to Starship’s 6, Super Heavy transfer tubes will also need to pump more than five times as much methane per second at full thrust, which could explain the larger diameter.

A normal Starship methane transfer tube with a thrust puck for scale. (NASASpaceflight – bocachicagal)
Larger-diameter transfer tubes arrived in Boca Chica late last month. Note the thrust puck – the same diameter as the puck one in the image above – at the far right of the trailer bed. (NASASpaceflight – bocachicagal)

Finally and perhaps most significantly, aerial photos from RGV Photography appeared to capture the first glimpse of what might be the hardest custom part required by Super Heavy – a thrust structure designed to support up to 28 Raptor engines. On December 10th, casually sitting between Starship Mk1’s remains (on the white concrete mount) and a tent, a flat ring with clear eightfold symmetry and a donut-like cutout large enough to fit a Starship thrust puck with room to spare was easily visible.

The hexagonal symmetry was the main giveaway, matching comments from CEO Elon Musk that Super Heavy’s thrust structure will feature a central ring of eight engines surrounded by an outer ring of up to 20 more Raptors. Assuming the first Super Heavy booster only flies with a few Raptor engines, that sole eight-engine ‘puck’ may be all that SpaceX needs to complete BN1.

Pictured here, the newest design iteration of Starship’s three-engine thrust puck features an integral methane transfer tube and has yet to fly. (NASASpaceflight – bocachicagal)

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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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SpaceX aces Starship’s 11th launch with success in every mission objective

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14 minutes ago

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October 14, 2025

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Credit: SpaceX

SpaceX aces its eleventh Starship test launch on Monday evening, marking the company’s second consecutive takeoff that crossed off each of the planned mission objectives.

It was also the final launch of the V2 Starship rocket. The twelfth test flight will feature the larger V3 Starship rocket, followed by V4, which will eventually make the first trip to Mars.

The launch was overwhelmingly successful. In its 12th test flight, SpaceX was able to achieve every major mission objective, including the second successful deployment of Starlink satellite simulators and the relight of a Raptor engine while in space. The latter achievement demonstrated “a critical capability for future deorbit burns,” the company said.

The ship officially launched at 6:23 p.m. local time in Starbase, Texas, with all 33 engines igniting and sending the Ship to space.

Stage separation occurred just over eight minutes later, and Super Heavy started its descent back to the Gulf of America, where it successfully splashed down. The first part of the launch was complete.

Starlink simulators were deployed about twenty-one minutes after launch, as the Pez dispenser sent the faux-satellites out to space without any issue:

Perhaps the most anticipated part of the launch was with Starship’s banking maneuver and subsequent splashdown in the Indian Ocean.

Prior to Starship 11’s launch and successful re-entry and splashdown, SpaceX had lost a few vehicles during this portion of the previous flights.

However, the company had made tremendous improvements and has now aced two consecutive launches. On Monday, its approach and splashdown were both overwhelmingly successful:

The re-entry phase of this particular Starship launch aimed to gather data on the performance of the heatshield, SpaceX said. The heatshield was intentionally stressed to its limits to determine how much it could withstand without failing.

SpaceX will now turn its focus to the next vehicles, including V3, which is larger, more capable, and will help the company gather even more information about its launches into space:

CEO Elon Musk has said the third-generation Starship rocket will be built and tested by the end of the year.

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Tesla launches new color from Gigafactory Berlin

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17 hours ago

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October 13, 2025

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Credit: Tesla

Tesla has launched a new color at Gigafactory Berlin in Germany, home of the company’s “world-class paint shop,” as Elon Musk once called it.

Bringing a new color to Tesla’s Model Y, there are now five available colors for those who will receive a vehicle from Gigafactory Berlin, with four of them being colors offered in other markets.

However, there is now one distinct color that is only available in Germany: Marine Blue.

Priced at €1,300, Marine Blue will cost the same as both Diamond Black and Stealth Grey, while Quicksilver and Ultra Red are available for double the price.

It is the third shade of blue Tesla offers across its lineup, as Deep Metallic Blue and Glacier Blue are also offered, but in other markets.

Tesla has routinely flexed Giga Berlin for having the most advanced paint shop throughout its factories, and it has produced some interesting colors over the past few years, some of which were truly awesome.

Tesla Giga Berlin is getting a world-class paint shop, new color ‘layers’ to come

In 2020, Musk said, “Giga Berlin will have the world’s most advanced paint shop, with more layers of stunning colors that subtly change with curvature.”

He also detailed the company’s plans to upgrade the Fremont and Shanghai paint shops. Gigafactory Texas was not yet unveiled. Tesla has worked to improve those facilities, especially in Fremont.

It was able to roll out the new Diamond Black color earlier this year.

However, Giga Berlin seems to remain the standard in terms of paint for Tesla. It routinely offers new colors.

For example, back in 2022, Tesla rolled out its familiar Quicksilver color for the Model Y, while also introducing Midnight Cherry Red, a color close to burgundy. However, the company chose to discontinue the color after determining internally that customers no longer wanted to buy it.

Midnight Cherry Red was removed as an option earlier this year, likely to make way for the development of the new Marine Blue.

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Tesla Autopilot visualization gets big upgrade with tons of new additions

The AP visualization shows up on the center touchscreen and illustrates the surroundings of the cars. It has gotten better in recent years, as it is able to outline types of vehicles, pedestrians, animals, and more.

Published

19 hours ago

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October 13, 2025

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Credit: @greentheonly | X

Tesla’s Autopilot visualization just got a big upgrade as the company added tons of new additions to what it will be able to render in terms of a vehicle’s surroundings.

The AP visualization shows up on the center touchscreen and illustrates the surroundings of the cars. It has gotten better in recent years, as it is able to outline types of vehicles, pedestrians, animals, and more.

Tesla just fixed a four-year-old bug with Full Self-Driving visualization

However, it still does not have every single application, and acquiring them will take some time. If an object or vehicle is visible to the vehicle but an accurate render is not available, the car will instead pick whatever is closest.

For example, I passed an Amish family yesterday in Lancaster, PA, and instead of illustrating the horse and carriage, it simply showed a small box truck.

In an effort to make the Autopilot and Full Self-Driving suites more robust and accurate, Tesla has added a substantial amount of vehicle renders, which will become available in the coming weeks.

The visualizations were found by Tesla hacker @greentheonly, who posted them on X.

The new visualization renders are:

  • Ambulance
  • Firetruck
  • Garbage Truck
  • Schoolbus
  • European Semi Truck
  • Golf Cart
  • Person on a Scooter
  • Person on a Skateboard
  • Stroller
  • Street Sweeper
  • Three-Wheeler
  • Trailer
  • Train
  • Tram
  • Person in a Wheelchair

Here is an image with all of the Autopilot visualization renders:

Credit: Green

The visualization is a crucial part of manual operation and can be considered a distinct advantage that Tesla has over other companies.

It continues to be an effort that Tesla invests heavily in, as it keeps refining the suite and making it more robust with additional visualizations and animations.

Recently, it was revealed that Tesla is planning to utilize Unreal Engine for driver visualization to create a realistic depiction of the vehicle’s environment. Tesla has not yet confirmed this, but coding found with the Model S and Model X showed it could be coming in the near future.

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