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SpaceX’s Starhopper readies for more ambitious Raptor-powered flight tests

On June 1st, SpaceX technicians began installing a new Raptor - this time SN04 - on Starhopper. (NASASpaceflight - bocachicagal)

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For the second time in two months, SpaceX technicians have begun to install a Raptor engine on Starhopper, a full-scale Starship testbed theoretically capable of low-velocity, moderate-altitude ‘hops’.

Back in late March, Raptor and Starhopper were joined for the first time, enabling a lengthy series of attempted tests that were followed by two engine ignitions and tethered hops before Raptor was removed for inspection. In the two months since that first round of integrated testing, SpaceX has significantly upgraded Starhopper and its spartan launch facilities, all focused on transforming the odd vehicle from a largely fixed test stand into a giant, mobile Grasshopper.

All the way back in 2012, SpaceX began testing Falcon 9 recovery and reusability concepts with a low-fidelity prototype known as Grasshopper – essentially a minimalist Falcon 9 first stage with ad hoc legs and a single Merlin engine. It supported a series of 8 major test flights – all successful and a source of valuable data – before the vehicle’s 2013 retirement. An upgraded Grasshopper – known instead as Falcon 9 Reusable Development Vehicle (F9R Dev1) – began testing around the same time and continued even higher altitude vertical takeoff/vertical landing (VTVL) tests until its untimely demise in August 2014.

Starhopper is quite similar, although it is also serving as a testbed for a far more varied range of technologies due to the fact that it has been developed before the inaugural launch of its namesake (Starship/Super Heavy). By the time SpaceX started Grasshopper/F9R tests, Falcon 9 had already completed several successful launches. With Starhopper, SpaceX is building and testing its first 9m-diameter ‘flight’ hardware, its first propellant tanks built out of steel, its first flight-capable rocket fueled by methane and oxygen, and its first mobile Raptor testbed, among numerous other things. The challenges are inherently much greater, but SpaceX has the luxury of taking the opposite approach it took towards Falcon 9 and building a launch vehicle entirely around its intended reusability, rather than trying to squeeze a method of reusability around an already-flying rocket.

Saurid Oddities

As noted by NASASpaceflight.com in a June 2nd article, SpaceX seems to be juggling its growing selection of newly-produced and tested Raptor engines in pursuit of Starhopper’s return to flight. According to the publication’s reliable sources,

“Up until recently, [SpaceX] was planning to utilize Raptor SN4 for [Starhopper’s first] untethered hops. However, the company has now decided to utilize this engine only for fit checks, and will instead perform the hops with SN5 – the latest Raptor to come out of SpaceX’s factory in Hawthorne, California.” – NASASpaceflight.com, June 2nd, 2019

This indicates that the Raptor engine delivered to Boca Chica on June 1st and currently in the process of being installed on Starhopper is actually more of a stand-in* for a future Raptor, SN05. The reasons behind this Raptor shuffle elude detection, but it’s possible that the simplest explanation – also posed by NASASpaceflight – is the correct one. By shipping a Raptor that may not be ready for flight tests, SpaceX could likely save anywhere from a few days up to a few weeks by doing everything short of lifting off under the powered of Raptor SN04.

*By all appearances, SN04 is a flight-grade Raptor that has completed assembly and likely been test-fired in McGregor, Texas. Why it may currently be resigned to a “stand-in” role is unknown.

Very curiously, upon Raptor SN04’s South Texas arrival, it appears that SpaceX technicians have indeed rapidly installed the engine on Starhopper, but in a position that is decidedly off-center. Pictured above, the photo could have simply caught the engine while technicians were moving it to its actual installation spot, but it could also indicate that SpaceX is speeding towards Starhopper’s first triple-Raptor test flights.

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Starhopper delays?

In line with the last-second switch from Raptor SN04 to Raptor SN05 as the engine-to-be for untethered hops, SpaceX has pushed the start of that test series from approximately May 31st to June 11th. More likely than not, the ~11-day delay is meant to allow time for Raptor SN05’s McGregor, Texas acceptance testing, given that – per CEO Elon Musk – the engine wasn’t even finished as of May 22nd.

On the other hand, with Raptor SN05 now scheduled to support Starhopper hop tests as early as mid-June, it begs the question of whether SpaceX is instead working towards expedited triple-Raptor testing. For unknown reasons, neither Raptor SN03 or SN04 are apparently ready to support flight operations, although both have been thoroughly hot-fired in McGregor. Perhaps each engine is a distinct prototype with a different level of experimental readiness, or perhaps SpaceX is just testing certain engines (like SN03) more extensively than others (SN05).

Regardless, SpaceX now seems to have 3-4 intact, functional Raptor engines (excluding SN01; destroyed during stress testing), 2-3 of which are actively testing or being worked on a day’s drive north of Boca Chica. SN02 – having successfully supported a brief duo of ignition tests with Starhopper – could still be intact and test-ready. SN03 is an unknown quantity, but SN04 is clearly in excellent shape and is probably close to flight-readiness if it isn’t already. This is to say that SpaceX likely already has three Raptors on hand that are capable of supporting multi-engine Starhopper testing, whether or not such a test regime would actually be valuable.

Musk has noted that both orbit-capable Starship prototypes will be far closer to finished products and will thus fly with “at least 3 engines” (3 sea level engines, as it would turn out) or even “all 6” (3 sea level, 3 vacuum-optimized). In the meantime, Starhopper stands with an off-centered Raptor, awaiting the arrival of a different Raptor to kick off a second hop test program. If nothing else, SpaceX’s Starship/Super Heavy development program is operating in a spectacularly hardware-rich fashion, lending itself to the breakneck-pace of iteration and improvement SpaceX is famous for.

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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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The Starship moon landing number NASA and Elon Musk can’t agree on

Musk disputes NASA estimate of 22 Starship launches for Moon landing, predicting 6 to 8.

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Concept rendering of SpaceX Starship landing on the moon via Grok

Elon Musk is disputing a new NASA safety panel estimate of how many Starship launches it will take to put astronauts on the Moon, saying the real number will be less than half the panel’s figure.

On Thursday, NASA’s Aerospace Safety Advisory Panel held its quarterly public meeting. Panel member Charlie Precourt, a former NASA astronaut, flagged the fueling process for SpaceX’s lunar lander as a major risk for Artemis IV, the mission planned to land a crew on the Moon in 2028. “We need to keep our eyes on numerous required fuelings for the lander,” Precourt said, according to Ars Technica. “I think the last estimate is around 22 flights.”

Ars Technica’s Eric Berger posted the comment on X, and Musk replied. “That’s way too high,” Musk wrote. “Actual number will be more like 6 to 8.”

The disagreement comes down to a basic problem with sending a ship as large as Starship to the Moon. Starship burns nearly all of its propellant just reaching Earth orbit, so it cannot continue on to the Moon without stopping for a refill. SpaceX’s answer is a gas station in space. First, a Starship that works as a storage tank, called a depot, is launched into orbit. Then a series of tanker Starships launch one at a time, dock with the depot and pump their leftover propellant into it. Once the depot is full, the lunar lander version of Starship launches, docks, fills up and heads for the Moon.

Every tanker trip is its own full rocket launch, which is why the count matters. More launches mean more time, more cost and more chances for something to go wrong before astronauts ever leave Earth. Berger estimated that even if SpaceX reaches twice weekly Starship launches by the end of 2027, filling a depot at the panel’s number would still take roughly three months.

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How many tankers are needed depends mostly on how much propellant each one can carry to orbit and how much is lost along the way. Starship’s fuel and oxygen are stored at extremely cold temperatures, and some of it slowly boils off while waiting in orbit. More is lost in each transfer. NASA appears to be working from what Starship can lift today, while Musk’s range assumes a more capable rocket.

Musk has pushed back on higher counts before. In 2021, after a government document suggested 16 launches, he called that “extremely unlikely” and said eight tankers would be the most required.

Much of the answer depends on hardware SpaceX has not finished flying. As Teslarati noted earlier this year, the company plans to carry out the refueling process with its upgraded V3 Starship, and Precourt described Artemis IV as carrying “a large number of firsts.” He also praised NASA Administrator Jared Isaacman’s team for working to clear obstacles for both SpaceX and Blue Origin, whose Blue Moon lander does not rely on orbital refueling for its first mission.

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Tesla’s secretive “Project Crystal Sun” gets a big green light in Texas

Fort Bend County approved four incentive agreements Thursday for Tesla’s proposed $10.1 billion solar factory.

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Elon Musk stands in profile against a clear blue sky, with a bright overhead sun shining above a vast landscape of Tesla solar panels stretching to the horizon, and a smaller Texas flag flying on a pole to his right.

Fort Bend County commissioners on Thursday approved a package of tax incentives for Tesla’s proposed $10.1 billion solar cell factory near Needville, Texas, giving the company one of the last local approvals it needs before it decides where to build. All four Tesla agreements passed 4 to 0.

The votes covered a property tax abatement inside Reinvestment Zone No. 34, a Chapter 381 economic development agreement, a foreign trade zone non-objection paired with payments in lieu of certain taxes, and a separate payment in lieu of taxes “true up” agreement, according to agenda notes from the Fort Bend Commissioners Court meeting.

The project, known internally as “Project Crystal Sun,” would make solar cells and finished modules on roughly 3,000 acres near FM 762 and FM 1994, south of the Brazos River. As Teslarati reported when the filing first surfaced in August, Tesla’s application under the state’s JETI Act splits the investment into $1.5 billion in real property and $8.6 billion in equipment, with 9,712 permanent jobs projected by 2033 and commercial operations targeted for the first quarter of 2029. The plant would handle the full chain from ingot and wafer production through cell testing.

Inside Tesla’s secretive $10 Billion “Project Crystal Sun” filing

Thursday’s approval does not lock in the site. Tesla has told the Texas Comptroller it is still weighing other locations, and site selection adviser David Dennison told Lamar Consolidated ISD trustees in September that the race had narrowed to Fort Bend and one out of state rival with a “very compelling package,” according to the Houston Chronicle. Tesla hopes to decide before the end of 2026, and the incentives still need sign off from the Comptroller and the Governor’s office.

Local officials have now done nearly everything within their control. Commissioners created the reinvestment zone in an August 24 special meeting, with Interim County Judge Daniel Wong formally withdrawing himself over his engineering firm’s past work with Tesla. Lamar CISD trustees voted 7 to 0 on September 15 to advance a JETI agreement that would tax Tesla’s qualifying property at 50 percent of its value for maintenance and operations from 2029 through 2038.

The plant lines up with a target Elon Musk set on Tesla’s Q4 2025 earnings call in January, when he said the company would “work toward getting 100 GW a year of solar cell production, integrating across the entire supply chain from raw materials all the way to finished solar panels.” In March, Tesla was reported to be negotiating a $2.9 billion purchase of Chinese solar manufacturing equipment bound for Texas. The Houston area already hosts Tesla’s Megafactory in Brookshire, where Megapack 3 production has started. Tesla said on its Q3 call that Megapack supply for 2027 is nearly sold out, and Musk wrote on X Thursday that the company is “increasing production of Megapacks as much as possible,” as demand from data centers climbs.

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Tesla is building its own maps to fix Navigation issues

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Credit: Tesla

Tesla revealed plans to develop its own maps internally to fix Navigation issues and give owners more control over their routing.

On the company’s Q3 2026 Earnings Call, a question was asked about FSD Navigation issues, particularly speed limit recognition, parking, and routing. These are issues that surface from version to version and seem to be seriously challenging for Tesla’s AI team to resolve.

Tesla’s Head of AI, Ashok Elluswamy, said in response to the question:

“You’re totally right that we shouldn’t be depending on external people’s maps. So we are building our own maps, but not like the same way as OneMoreMap. We are building an entirely new architecture with essentially AI-based mapping and navigation.”

He continued:

“It’s going to be super awesome. It’s going to be integrated with voice. You can talk to it, ask for different routes. It’s going to learn your personalized preferences, plus the fleet preferences. The collective intelligence of all the cars is going to flow into making the maps and navigation super cool.”

Elluswamy said this issue should be confronted, and the mapping should be available for people by the time the v15 release starts deploying to customers.

“And over the next several months,” he added, “it’s just going to take over all of the navigation functions, parking, destination handling. And it will know you better than you know yourself in some regard for the driving task, and then handle it fully.”

Tesla Summon got insanely good in FSD v14.3.2 — Navigation? Not so much

Navigation is perhaps the most notable complaint with FSD, and although it has gotten better, it is still flawed. Much of the time, FSD will take people on routes that are not preferred by the driver, but Tesla tried to combat this with a routing feature in the Summer 2026 Update.

Tesla currently relies on Google for map data, but it is sort of counterintuitive to believe the company would rely on a third party for this. These improvements will be welcome, as routing and navigation have been such a pain point for so many owners for so long.

Quotes via Motley Fool

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