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SpaceX installs Starship Mk1 rocket’s flaps for the second time in build-up to flight debut
A little over a month after SpaceX CEO Elon Musk presented an update on Starship in Boca Chica, Texas and technicians dressed the rocket up for the show, SpaceX has begun to install Starship Mk1’s flaps for the second time.
This time, with any luck, those flaps are here to stay until Starship Mk1’s inaugural launch debut, an ambitious flight test with a target altitude of 20 km (12 mi).
Around the second half of September, SpaceX technicians appeared to begin working around the clock to fully assemble Starship, outfitting the exterior with the beginnings of plumbing, power lines, and avionics harnesses, stacking the Mk1 prototype’s two halves, and installing the vehicle’s large fore and aft flaps. During SpaceX CEO Elon Musk’s September 28th Starship update, what looked to be the largely finished Starship Mk1 served as the main backdrop – an undeniably impressive one, at that.
As would soon become clear, SpaceX’s September 2019 Starship Mk1 integration was actually more of a mock-assembly – all the parts involved appear to genuinely be real flight hardware, but almost all of it was only temporarily attached to Starship to give the partial appearance of a finished ship. By October 1st, technicians began removing Starship Mk1’s four flaps, flap shrouds, and leg shrouds, finally culminating in the separation of the rocket prototype’s upper and lower halves.
The fact that neither Musk or SpaceX spokespersons noted that Starship wasn’t actually complete is at least a little unsavory, although it’s admittedly unsurprising given CEO Elon Musk’s known affinity for grand gestures and events. On a positive note, Starship’s mock-assembly likely served as an excellent learning experience for the Boca Chica team and thankfully only seems to have caused a week or two of delay.
Rapid progress in Boca Chica
Despite the mild disruption of dressing Starship Mk1 up for Musk’s presentation, SpaceX Boca Chica has made a huge amount of progress in the five weeks since. Barely three weeks after the rocket’s forward flaps (canards) were removed, SpaceX technicians began the reinstallation process with one major visible difference: a massive motorcycle-sized actuator.
On the first round of installations-for-show, Starship Mk1’s flaps featured no such mechanism, confirming suspicions that much of the hardware installed at the last second was not quite finished or was only being installed for Musk (and practice). The appearance of a previously unseen actuator mechanism on the first reinstalled canard suggests that this time around, SpaceX is installing Starship’s flaps with their final purpose of controlling Starship’s free-fall in mind.
Instead of copying Falcon 9’s proven method of vertical launch and vertical landing, SpaceX is taking a more radical approach with Starship that will see the spacecraft reenter Earth’s atmosphere belly-first, slow its forward speed to near-zero, and fall directly down for approximately 25 km (15.5 mi), using its flaps like a skydiver’s limbs. Perhaps just a few hundred meters above the ground, Starship will finally perform an aggressive flip maneuver, igniting its Raptors while sideways, swerving to neutralize that horizontal velocity, and finally landing on six small legs.
In this sense, although they certainly look the part, Starship’s aerodynamic control surfaces are very explicitly not wings and are instead meant to interact with the atmosphere at an almost 90-degree angle of attack (AoA). In line with that strategy, they only have to actuate with a single degree of freedom, drastically simplifying Starship’s control surfaces.
Similar to Starship Mk1’s newly filled-out canard actuators, SpaceX technicians have installed two massive hinges/mounts for Starship’s larger after flaps. Aft flap installation will likely start as soon as SpaceX technicians have installed the bulk of Starship Mk1’s external plumbing and wiring, a milestone that appears to be fast approaching.
Starship Mk1’s lower half was unexpectedly moved about a mile to SpaceX’s nearby launch facilities prior to the installation of its nose section, meaning that SpaceX will likely have to transport the nose to the launch pad for final mating. It’s unclear what tests SpaceX specifically plans to kick off Starship Mk1’s pre-flight preparations with, but it’s safe to assume that the most imminent milestone is a wet dress rehearsal (WDR), possibly preceded by a tank proof test.
The latter procedure would be designed to prove that Starship Mk1’s pressure vessel is both leakproof and structurally sound and would nominally involve filling the spacecraft’s tanks with a neutral fluid (likely water or liquid nitrogen). A WDR would see SpaceX load Starship as if preparing for launch (requiring liquid oxygen, methane, nitrogen, and helium) but stopping just prior to the engine ignition and liftoff that would otherwise follow. Although unlikely, a WDR could result in a massive fire or explosion if Starship were to lose structural integrity during the test, which is why the aforementioned neutral testing is typically performed first when handling brand new launch vehicles.
Finally, assuming Starship Mk1 successfully passes the above tests, SpaceX will use the vehicle to perform Raptor’s first triple-engine static fire test. That static fire will likely be the final major test activity before SpaceX readies Starship Mk1 for its 20-km flight debut, which will serve as a more or less full-fidelity test of Starship’s exotic skydiver-like landing.
Regardless of how exactly Starship Mk1’s imminent test campaign will play out, SpaceX has road closures scheduled on November 7th, 8th, and 12th. Right now, it’s anyone’s guess what is planned for Thursday and Friday, but it could potentially involve a tank proof test, launch pad checkouts, propellant loading, or something more benign, like transporting Starship’s nose section to the pad for final installation. Stay tuned!
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Tesla is using a redesigned Cybertruck battery cell to mitigate Semi challenges
It is perhaps the most recent example of Tesla using unique engineering prowess and cross-pollinating vehicle elements to solve common problems, something it does better than most companies out there.
Tesla revealed that it is utilizing redesigned Cybertruck battery cells in its Long Range Semi to mitigate some pertinent challenges that come with long-haul logistics.
It is perhaps the most recent example of Tesla using unique engineering prowess and cross-pollinating vehicle elements to solve common problems, something it does better than most companies out there.
Tesla’s long-awaited Semi truck is entering production at its Nevada Gigafactory, and fresh factory footage reveals a clever evolution in its battery technology.
The Long Range variant, designed for up to 500 miles of real-world range, relies on a structural battery pack that uses the same 4680-form-factor cells found in the Cybertruck.
However, Tesla engineers have completely redesigned the pack’s architecture—shifting from the flat, pancake-style modules typical in passenger vehicles to a compact, vertical cubic layout. This change isn’t just about cramming more energy into the chassis; it’s a targeted solution to one of electric trucking’s biggest headaches: range loss in cold climates.
Dan Priestley, Head of the Tesla Semi program, said:
“We’re using essentially the same cell out of Cybertruck, but our cars packs are more like a pancake. Whereas these are more like a cube. You get a lot of energy stored in a small space. You can only do this if you design the vehicle to be electric from the ground up.”
Here, in all its glory, is the exclusive first look at the massive @Tesla Semi factory.
Our @corememory crew went to Nevada to see the line come to life, as it gets ready to pump out thousands of all-electric trucks. We saw the new cab and went on a drive too. Wunderbar! pic.twitter.com/a0S5zVEr87
— Ashlee Vance (@ashleevance) April 10, 2026
In conventional EVs, battery packs are laid out horizontally in wide, flat arrays to fit under the floor. While this works for cars and even the Cybertruck’s structural pack, it exposes a large surface area to the elements.
Heat escapes quickly, especially overnight when the truck is parked. Cold temperatures slow chemical reactions inside lithium-ion cells, reducing available energy and forcing the vehicle to expend extra power warming the battery and cabin.
Real-world tests on vehicles like the Cybertruck show winter range losses of 20-40 percent, depending on conditions. For long-haul truck drivers operating in Canada, Scandinavia, or the northern U.S., this “silent killer” means unplanned stops, reduced payloads, and higher operating costs.
From personal experience, cold weather still impacts EV batteries even with various inventions and strategies that companies have come up with. In the cold Pennsylvania winter, charging was much more frequent for me due to range loss due to temperatures.
Tesla’s cubic battery pack flips the script. By arranging the 4680 cells in tall, dense vertical stacks, the pack minimizes external surface area relative to its volume—essentially turning the battery into its own thermal blanket.
Factory video from the Semi assembly line shows these large, yellow-green structural modules mounted directly onto the chassis, forming a near-cube shape.
The reduced exposure helps the pack retain heat generated during operation, keeping cells closer to their optimal temperature even after hours in sub-zero conditions.
The design doesn’t stop there. Tesla pairs the cubic pack with an advanced heat pump system that actively recycles thermal energy from the motors, brakes, and even ambient air.
Tesla reveals various improvements to the Semi in new piece with Jay Leno
Unlike passive systems in earlier EVs, this architecture transfers waste heat back into the battery, maintaining readiness for morning departures without draining the pack.
Executives have noted that the combination, cubic geometry plus intelligent thermal management, dramatically cuts overnight cooldown and range degradation, making the Semi viable for 24/7 fleet operations in harsh winters.
Beyond cold-weather performance, the redesigned pack integrates structurally with the truck’s frame, enhancing rigidity while simplifying assembly. Production footage shows workers installing the massive modules early in the line, signaling that the Semi’s battery is now a core chassis component rather than an add-on.
Using proven 4680 cells keeps costs down and leverages Tesla’s scaled manufacturing know-how from Cybertruck and Model Y lines.
Tesla’s focus on ramping up Semi output will lean on small innovative steps like this one. Truckers are not immune to traveling in cold weather conditions, and changes like this one will help make them more effective while also increasing output by logistics operators who choose to go all-electric with the Tesla Semi.
Elon Musk
SpaceX is keeping the Space Station alive again this weekend
SpaceX’s Falcon 9 launches Northrop Grumman’s Cygnus NG-24 to the ISS with 11,000 pounds of cargo Saturday.
SpaceX is targeting April 11 for the launch of Northrop Grumman’s Cygnus XL cargo spacecraft to the International Space Station, carrying over 11,000 pounds of supplies, science hardware, and equipment for the Expedition 73 crew aboard. Liftoff is set for 7:41 a.m. ET from Space Launch Complex 40 at Cape Canaveral Space Force Station, with a backup window available April 12 at 7:18 a.m. ET.
The mission, officially designated NG-24 under NASA’s Commercial Resupply Services program, names its spacecraft the S.S. Steven R. Nagel in honor of the NASA astronaut who flew four Space Shuttle missions and logged over 723 hours in space before his death in 2014. Unlike SpaceX’s own Dragon capsule, which docks autonomously, Cygnus relies on NASA astronauts to capture it using a robotic arm before it is berthed to the space station’s module for unloading. When the mission wraps up around October, the Cygnus will depart loaded with station trash and burn up on reentry.
Countdown: America is going back to the Moon and SpaceX holds the key to what comes after
This is the second flight of the Cygnus XL configuration, which debuted on NG-23 in September 2025 and offers a roughly 20% increase in cargo capacity over the previous design. Northrop Grumman switched to Falcon 9 launches after its own Antares 230+ rocket was retired in 2023 following supply chain disruptions from the war in Ukraine.
The upcoming cargo includes a new module to advance quantum research, and an investigation studying blood stem cell production in microgravity with potential therapeutic applications on Earth.
The NG-24 mission is one piece of a much larger picture for SpaceX and the U.S. government. As Teslarati reported, SpaceX has become an indispensable launch provider for U.S. national security missions, picking up a $178.5 million Space Force contract in April 2026 to launch missile tracking satellites, while also holding roughly $4 billion in NASA contracts tied to the Artemis lunar program.
At a time when no other American rocket can match the Falcon 9’s combination of reliability, cost, and launch cadence, Saturday’s mission is a straightforward reminder of how much the U.S. government now depends on a single commercial provider to keep its astronauts supplied and its satellites flying.
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Tesla hits FSD hackers with surprise move
In recent weeks, the company has begun remotely disabling FSD capabilities on affected vehicles, and in some instances, permanently revoking access even for owners who paid thousands of dollars for the feature.
Tesla is cracking down on hackers who have figured out a way to utilize third-party programs to activate Full Self-Driving (FSD) in their vehicles — despite the suite not being approved for use in their country.
Tesla has launched a sweeping enforcement campaign against owners using third-party hardware hacks to activate FSD software in countries where the advanced driver-assistance system remains unregulated or unapproved.
In recent weeks, the company has begun remotely disabling FSD capabilities on affected vehicles, and in some instances, permanently revoking access even for owners who paid thousands of dollars for the feature.
Tesla has started remotely disabling Full Self-Driving on cars fitted with third-party CAN bus hacks in countries where the software is not yet approved.
This crackdown began after the hacks started spreading widely last month. 👇 pic.twitter.com/wL8VqZuTlK
— PiunikaWeb – helpful, and breaking tech news (@PiunikaWeb) April 9, 2026
Reports of the crackdown have surfaced across Europe, China, Japan, South Korea, and the UK, marking a significant escalation in Tesla’s efforts to enforce regional software restrictions.
FSD is Tesla’s flagship supervised autonomy package, which is available in several countries across the world. Currently limited by regulatory hurdles, it has not received full approval in most markets outside of the United States due to various things, such as safety standards, data privacy, and local traffic laws.
However, the company is working to expand its availability globally. Nevertheless, Tesla has installed the necessary hardware on vehicles globally, but locks the features based on geographic location.
Some owners have taken accessing FSD into their own hands, using jailbreak or bypass devices.
These “jailbreak” tools, typically €500 USB-style modules that plug into the vehicle’s Controller Area Network (CAN) bus, intercept signals to spoof approvals and unlock FSD, including advanced navigation, Autopark, and Summon features.
Hackers in Poland, Ukraine, and elsewhere have distributed the devices, with some claiming they work on HW3 and HW4 vehicles and can be unplugged to restore stock settings. In China alone, over 100,000 owners reportedly installed such modifications.
Tesla’s response has been swift and uncompromising. Recently, the company began sending in-car notifications and emails warning owners that unauthorized modifications violate terms of service, compromise vehicle safety systems, and expose cars to cybersecurity risks.
The email communication read:
“Your vehicle has detected an unauthorized third-party device. As a precaution, some driver assistance functions have been disabled for safety reasons. A software update will be available soon. Once you install the update, some features may be enabled again.”
Vehicles detected using the hacks have had FSD capabilities remotely disabled without refund. In some cases, owners report permanent bans, even if they had legitimately purchased the software package.
Tesla’s hardline stance underscores its commitment to regulatory compliance and safety.
Tesla has long argued that unsupervised FSD requires rigorous validation, and premature activation could endanger drivers and bystanders.
The crackdown sends a clear-cut message to those who are bypassing the FSD safeguards, but there are greater implications for Tesla if something were to go wrong. This is an understandable way to protect the company’s reputation for its FSD suite.
Tesla is using a redesigned Cybertruck battery cell to mitigate Semi challenges
SpaceX is keeping the Space Station alive again this weekend
