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SpaceX to build small version of BFR’s spaceship for use on Falcon 9, says Elon Musk

A view of spaceship (BFS) separating from BFR booster (BFB). (SpaceX)

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SpaceX CEO Elon Musk has taken to Twitter to announce a new development program: in order to gain experience with the new design and recovery strategy, SpaceX engineers and technicians will apparently build a miniature version of BFR’s winged spaceship able to launch atop Falcon 9 or Falcon Heavy.

According to Musk, the company aims to conduct the first orbital flight of this mini-BFS as early as June 2019, just eight months away.

Described as a “SpaceX tech tree build”, Musk seems to be implying that the strategic purpose of this new development is to act as a stepping stone between Falcon 9 and BFR, two dramatically different launch vehicles relying on a variety of entirely distinct technologies. Based on the fact that Musk believes the mini-BFS could reach orbit as early as June 2019, it seems likely that the miniature spaceship will essentially just be a strengthened Falcon 9 upper stage with fins and a heat shield attached versus a more extreme departure, where the stage would literally be a mini-BFS.

In the latter scenario, SpaceX could use the opportunity to extensively test – albeit on a smaller scale – a number of immature BFR technologies, including all-composite propellant tanks, autogenous pressurization, a sea level-optimized rocket engine on an orbital upper stage, methane and oxygen (methalox) propellant, actuatable tripod fins, new heat shield materials, and more. If SpaceX has been working on this for several months, there is still a chance that those technologies will be tested on this step-change Falcon 9 S2 variant, but it seems improbable that Musk would have been able to stay totally silent on the plans during his September 2018 update to the BFR program.

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Falcon 9 upper-stage recovery

Going off of what little information we have, it seems more likely that the “mini-BFR ship” described by Musk is an effort to realize Falcon 9 upper stage recovery and test BFR’s orbital spaceship recovery strategies than it is an extensive development platform for all critical BFR technologies. Prior to today’s tweet, Musk announced early this year (April, to be precise) that SpaceX would attempt to recovery Falcon 9’s upper stage with a “giant…balloon”, or an inflatable decelerator to use the technical terminology.

Given this new development, it’s unclear if those plans are still on – as a small spaceship, Falcon 9’s upper stage would likely be able to reenter Earth’s atmosphere without the need for something like a single-use inflatable decelerator, which would have always been a suboptimal crutch for the recovery of any orbital spacecraft, be it Falcon 9 or BFR. With this new plan, it appears that SpaceX wants to kill at least two birds with one stone, building a platform capable of flight-testing a handful of new technologies critical to BFR’s success while also potentially realizing the dream of a fully-reusable Falcon 9.

A gif of Raptor throttling over the course of a 90+ second static-fire test in McGregor, Texas. (SpaceX)

Given recent reports from Reuters that Musk has demanded that SpaceX’s Starlink team work towards the first launch of an operational batch of satellites by mid-2019, his target date for a mini-BFS Falcon 9 upper stage is likely no coincidence. Given the potential risk of being the first to launch on an unproven variant of Falcon 9, it’s possible (if not probable) that SpaceX will conduct its own launch of the rocket prior to flying paying customers – a perfect way to avoid wasting that launch would be risking a few of SpaceX’s own Starlink satellites in place of a customer’s payload.

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Musk seems to be confident that SpaceX has effectively ‘solved’ propulsive rocket landings, stating that the purpose of this new variant will be dedicated to testing an “ultra light heat shield and high Mach control surfaces”. Judging from a number of recent job postings focused on new thermal protection systems (and affixing them to composite structures) and an official request for information (RFI) from NASA Ames about its lightweight TUFROC heat shield material, this is a major focus and one of several critical paths for BFR development.


For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet check out our brand new LaunchPad and LandingZone newsletters!

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 completes another secret Pentagon launch, adding to suspected Starshield buildout

SpaceX launched the classified USSF-385 mission from Vandenberg, landing its booster on a tenth flight.

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US Golden Dome space defense system (Concept render by Grok)

SpaceX launched another classified mission for the U.S. Space Force from California early Saturday morning, and the Falcon 9 booster that carried it landed on a drone ship in the Pacific for the tenth time. The USSF-385 mission lifted off from Space Launch Complex 4E at Vandenberg Space Force Base at 7:00 a.m. PT.

Booster B1100 touched down on Of Course I Still Love You roughly eight and a half minutes after liftoff. It was the booster’s tenth flight and tenth successful landing, following the NROL-95 national security mission and eight Starlink launches. Its previous flight, a Starlink Group 15 mission on August 22, came just 35 days earlier. SpaceX ended its livestream shortly after the landing, which is standard for classified payloads, and neither the company nor the Space Force has said what the rocket carried.

USSF-385 is the fourth Space Force launch from the same Vandenberg pad in roughly six weeks, following USSF-366 on August 15, USSF-153 on September 10, and USSF-259 on September 17. When SpaceX flew USSF-366 in August, independent trackers noted that the rocket’s stage drop zones matched SpaceX’s Starlink Group 15 missions, pointing to Starshield, the government version of the Starlink satellite bus. The Space Force later cataloged 23 satellites after both USSF-366 and USSF-153, while USSF-259 placed 17 satellites into a different orbital plane, per KeepTrack. Launch databases describe USSF-385 the same way, though the payload remains officially unidentified.

Starlink’s Starshield wins contract with US Space Force

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The cadence lines up with the contracts, because in July, the Space Force awarded SpaceX $1.6 billion in task orders for 18 Falcon 9 missions from Vandenberg through the end of 2027. SpaceX also holds contracts to build pieces of that same network, which pushed its Pentagon contract total for 2026 past $8 billion.

Saturday’s flight was also the sixth and final Falcon 9 launch from Vandenberg in September, according to Spaceflight Now, while only one Falcon 9 flew from the East Coast this month as SpaceX shifts its Florida infrastructure toward Starship. Launch trackers list it as SpaceX’s 112th mission of 2026 and the 108th Falcon 9 flight of the year, with SLC-4E turned around about six and a half days after its previous launch.

The West Coast pad will not stay quiet for long, considering SpaceX has another Starlink mission scheduled from SLC-4E on September 30. Meanwhile, in Texas, the company is two days away from Starship Flight 14, which is targeting Monday at 7:15 a.m. CT for the vehicle’s first attempt to reach orbit.

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Tesla hints at new Roadster design in surprise clip

Tesla ended its Semi event with a Roadster teaser revealing a new front light bar.

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Tesla Battery Day event (Credit: Ryan McCaffrey/Twitter)

Tesla closed out its Semi event in Nevada on Thursday night with a nod to its own history, dropping a short Roadster teaser that suggests the production car will look noticeably different from the prototype first shown in 2017.

“We can’t have a Semi event without the Roadster,” Tesla engineering executive Lars Moravy told the crowd before the clip played. The line was a deliberate callback. Tesla first revealed the next generation Roadster in November 2017 by driving it out of the back of a Semi trailer at the truck’s original unveiling in Hawthorne, California.

The new video opens on trailer doors swinging apart in the dark. A thin white light bar glows across what appears to be the nose of the car, Tesla and SpaceX logos flash over the frame, and the Roadster name appears before the clip ends on “See you next week.” Tesla posted the nine second clip on X after the livestream wrapped.

The light bar is the most concrete design detail so far. The 2017 prototype used two separate curved headlamp pods, while a connected front light strip would bring the Roadster in line with the Cybertruck, Cybercab, Semi, and refreshed Model Y. Sawyer Merritt was among the first to point out what looked like part of a SpaceX logo in the video, something Tesla has not addressed.

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That logo fits the buildup around the optional SpaceX Package, which Elon Musk has long said would use cold gas thrusters to improve acceleration and possibly allow the car to briefly leave the ground. Tesla’s “Go for launch” post on September 12 set the October 1 date, and invitations sent to reservation holders place the event in Waco, Texas, at 8:30 p.m. Eastern. Waco sits roughly 20 minutes from SpaceX’s McGregor rocket test site, where the FAA has put a temporary flight restriction in place from September 18 through October 2, covering a 1.5 nautical mile radius from the surface up to 10,000 feet.

Tesla is also taking money ahead of the reveal. The company reopened Roadster reservations earlier this week with a $5,000 refundable card payment, followed by a $45,000 wire transfer due within 10 days. That puts buyers at $50,000 committed before Tesla has published a price.

The original pitch set a high bar: 0 to 60 mph in 1.9 seconds before any upgrades, 620 miles of range, a top speed above 250 mph, and production in 2020. That timeline has slipped repeatedly, and Tesla has since pointed to production at Gigafactory Texas no earlier than 2027. The company has said next Thursday’s event will include pricing, specifications, and production targets, the three details original reservation holders have been waiting on for nearly nine years.

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SpaceX readies Starship Flight 14 for a historic journey into uncharted territory

SpaceX finished Starship’s Flight 14 rehearsal, clearing the way for its first orbital flight Monday.

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Sunrise at Starbase. Starship is stacked for opportunistic full-stack testing ahead of Flight 14 via SpaceX
Sunrise at Starbase. Starship is stacked for opportunistic full-stack testing ahead of Flight 14 via SpaceX

SpaceX has cleared one of the last hurdles before Starship’s first trip to orbit. The company posted on X Thursday afternoon that its launch rehearsal for Flight 14 was complete, keeping the mission on track for Monday, September 28. The launch window opens at 7:15 a.m. CT at Starbase, Texas, and runs for 75 minutes.

A wet dress rehearsal is essentially launch day without the launch. Crews fill Booster 21 and Ship 41 with thousands of tons of extremely cold propellant, run the countdown nearly to ignition, then drain everything back out. It lets engineers catch leaks or equipment problems before anything leaves the pad. SpaceX still needs a launch license from the FAA before the stack, which stands 407 feet tall, can fly.

Flight 14 matters because of where it is going. All 13 previous Starship flights followed a suborbital path, which works like throwing a ball extremely high and far: the vehicle reaches space, but it is always on a course that brings it back down within about an hour. This time, Ship 41 will perform a short engine firing called an orbital insertion burn roughly 25 minutes after liftoff, giving it enough speed to keep falling around Earth instead of back into it. SpaceX plans about six laps at an altitude near 275 kilometers (171 miles) over nearly 10 hours, as Teslarati detailed when the mission was first announced.


Getting into orbit also means Starship has to prove it can get back out. The ship must relight a single Raptor engine in space to slow down for reentry. SpaceX says it will only attempt the orbital insertion burn after flight controllers confirm the hardware needed for that return burn has enough backup, and its flight plan includes health checks that could shorten the mission to two or five orbits.

Flight 14 is also the first to put working satellites into service. Flight 13 carried 20 Starlink V3 satellites in July, but they came back down with the ship because that mission never reached orbit. This time, 26 V3 satellites are meant to stay up and join the constellation within a few weeks. Together they add about 26 terabits per second of network capacity, which SpaceX says is roughly 10 times what a single Falcon 9 launch of older V2 Mini satellites adds. Three of them carry cameras that will photograph Starship’s heat shield in orbit to check for tile damage before reentry.

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The hardware has changed too. Ship 41 flies with extra fasteners on tiles in the most vulnerable areas, fixes for gaps where superheated plasma slipped behind tiles, and curved tiles designed to reduce heating between them. Two tiles recovered from Ship 40 will fly again, the first reuse of any part of a Starship heat shield. Booster 21 carries better engine filtering and new relight software after ice clogged three center engines on the previous booster, leaving only eight of 13 engines to restart for its landing burn.

Ship 41 is targeting a splashdown in the Pacific Ocean west of Chile, a new recovery zone after several Indian Ocean landings, while Booster 21 aims for the Gulf. Neither will be caught by the tower on this flight. Elon Musk said in August that a ship catch was likely “in a few months.”

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