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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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Elon Musk’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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Investor's Corner

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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