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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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Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says

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Credit: United Airlines

United Airlines CEO Scott Kirby said that SpaceX’s Starlink satellite internet is its leading competitive advantage in the U.S. airline industry. However, in recent comments, while he described the service as “the biggest competitive advantage” the carrier currently holds, he also acknowledged that the edge is temporary.

“…everybody eventually is going to have high-speed low earth orbit internet connectivity. It’s going to be a must-have. We are going to have a few years of being the only airline that has it at scale, and that’s our mission,” Kirby said. Until everyone has it, United aims to capitalize on its head start by converting trial users into long-term loyal customers.

United has moved faster than its rivals on Starlink installations. As of mid-to-late October 2026, the system was on roughly 43 percent of its fleet, with plans to reach 61 percent by year-end, 87 percent by June 2027, and full fleet coverage by the end of next year.

The airline already operates more Starlink-equipped flights than the rest of the U.S. industry combined. Los Angeles International Airport is scheduled to become United’s first 100 percent Starlink hub in the first half of 2027, and the carrier’s app will display the likelihood that any given flight has the service.

Kirby has pointed to early evidence that the offering influences booking decisions. Some passengers loyal to other airlines are already switching flights for Starlink connectivity, something the airline, along with American Airlines, has tried to leverage against competing airlines. Both companies used status-match programs, and some of those customers are pursuing company-specific credit cards, which signals an intent to stay.

Once onboard, these customers encounter the airline’s broader investments in aircraft, larger seat-back screens, oversized bins, connection tools, and a mobile app that Kirby says outperforms competitors. Wi-Fi satisfaction scores on Starlink-equipped planes have been reported to be nearly double those on aircraft with other systems.

Competitors are moving slowly to do the same. Southwest Airlines began installations in 2025 and expects to complete them soon. Delta is pursuing Amazon’s Leo system, while American expects to start Starlink work in early 2027 and has not yet detailed regional-fleet plans. This timeline gap gives United a multi-year window in which it remains the only major U.S. carrier offering Starlink at scale.

Kirby has framed the strategy as pressing that advantage while simultaneously widening gaps in other technology areas so that customers who try United for the Wi-Fi remain for the overall experience.

The approach reflects a calculated bet that superior in-flight connectivity can accelerate share gains and support longer-term financial targets, including a 10 percent pre-tax margin goal.

High-speed internet is particularly valued by premium and business travelers who can work or stream reliably. As low-Earth-orbit service becomes ubiquitous, the temporary nature of the pure connectivity edge means United’s retention will depend on whether its other product and operational improvements keep pace.

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Tesla Cybercab’s unorthodox paint process explained

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Credit: Tesla

Tesla Cybercab skips the traditional paint shop entirely, marking an unorthodox process for coloring the fully autonomous vehicle. However, the decision was a smart one, as it slashed factory costs, floor space utilization, and complexity, since Tesla relied on specialized alloys and in-mold coloring.

Munro Live was given the opportunity to do a factory walkthrough with Tesla Vice President of Vehicle Engineering Lars Moravy, who explained and detailed how Cybercab production at Giga Texas eliminates one of the automotive manufacturing industry’s most expensive and space-hungry elements.

A conventional paint line can cost hundreds of millions of dollars and require a million man-hours to build. Moravy framed the choice around Tesla’s core rule: “Question the requirements: why do you need paint?”

The structural answer lies in material selection. The aluminum alloys used in Cybercab’s front and rear castings do not oxidize and lose strength over time, the way many common automotive aluminum alloys do. Only the side modules, built around hot-stamped boron-steel door rings, receive an anti-corrosion e-coat, or dip coat. Front and rear modules skip coating altogether.

Model Y and Model 3 bodies, by contrast, are fully coated and painted.

Exterior colors come from the plastics shop, which Tesla engineers described as “our paint shop” for the Cybercab. Body panels are produced via reaction injection molding, referred to as RIM. Color is then mixed into a polyurethane resin at the mix head immediately before injection, so the panel emerges already colored with a Class-A surface.

Robots trim overflow to control sink marks and flow lines. The process avoids conventional spray-paint defects like orange peel and paint bleed. Scratches can still be repaired with compatible coatings that behave “basically like paint.” Because color is integral rather than a surface layer, shallow scratches do not expose a contrasting undercoat.

The secret behind Tesla’s Cybercab Gold goes well beyond just the color

Tesla has also explored related approaches, including in-mold lamination and painted films on stamped panels.

The manufacturing payoff is substantial because removing the paint shop, combined with the “unboxed” modular process that builds and tests front, rear, side, and center modules in parallel before a short final assembly, cuts factory floor space per vehicle by about 50 percent.

Final assembly itself uses only about 25 automated stations, far fewer than the typical Model Y line, and the overall line runs at about 78 percent automation, Moravy said. The approach also eliminates volatile organic compound emissions associated with traditional spray painting for these panels and shortens the coloring cycle from hours to minutes.

Cybercab’s paint strategy is clearly less about aesthetics than about systematically deleting capital-intensive, energy-heavy, and space-consuming steps once material science and process design make them unnecessary. It is a concrete example of Tesla applying first-principles questioning to one of the auto industry’s most entrenched factory requirements.

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Investor's Corner

Tesla has a Cybercab problem nobody saw coming

Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.

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Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”

Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.

The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.

Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.

The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.

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The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.

Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”

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