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SpaceX’s BFR program pursuing advanced Starship heat shield with NASA help

BFS/Starship shows off some of its heat shield. SpaceX may be looking into an advanced NASA solution for BFR's thermal protection system. (SpaceX)

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According to a Space Act Agreement signed by SpaceX and NASA’s Ames Research Center in June 2018, the private company has begun working with NASA to acquire some basic experience and lessons-learned with a thermal protection (heat shield) material that is largely new to SpaceX.

Known as TUFROC (short for Toughened Uni-piece Fibrous Reinforced Oxidation-Resistant Composite), the NASA Ames-developed material is capable of withstanding temperatures as high as 1700 C (~3100 F) and is apparently an item of interest to SpaceX’s next-gen BFR (Starship/Super Heavy) rocket program, particularly Starship’s heat shield.

TUFROC’s carbon cap glows during 3000F (1700C) arc-jet testing at NASA Ames. (NASA)

As far as the public is aware, SpaceX has never attempted to manufacture or utilize a heat shield technology like TUFROC. Falling under a domain of thermal protection materials known as ceramic matrix composites (CMCs), TUFROC is essentially an umbrella term that covers any thermal protection system that combines a carbon cap, silica base, and a cured glass coating to prevent oxidation. In recent years, Boeing’s secretive X-37B spaceplane has successfully demonstrated TUFROC reuse after orbital velocity reentries, confirming that the material is capable of surviving those conditions while experiencing minimal to no ablation.

Much like SpaceX borrowed the NASA-developed PICA (phenolic-impregnated carbon ablator) heat shield technology and dramatically improved it for cost-effective use on Cargo (and soon Crew) Dragon, the basic concept behind TUFROC’s heat shielding capabilities likely lends itself just as well to potential improvements in cost reduction, ease of manufacturing, mechanical strength, thermal protection characteristics, and more.

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Unlike the fatally fragile carbon-carbon tiles used on the Space Shuttle, TUFROC’s namesake “Fibrous Reinforced” aspects also make it dramatically more resistant to impact related forces like those that led to the Columbia disaster, while still preserving the composite’s impressive heat resistance. NASA already categorizes TUFROC as a “low-cost” TPS, further indicating that SpaceX could quite easily cut the cost of production by a significant degree.

 

What is not clear about this budding relationship is how exactly SpaceX foresees TUFROC or a custom heat shield derivative fitting into its BFR program. Currently, the TPS has only been demonstrated on X-37B as a literal edge-case, standing in for a more traditional silica tile on the leading edges of the small spacecraft’s wings, where reentry heating is often the most extreme. It’s possible that SpaceX is interested in TUFROC for the same reasons – using it to cover BFS/Starship’s forward and rear fins and nothing more.

However, it could be the case that SpaceX hopes an improved TUFROC-X might be viable as a monolithic one-size-fits-all heat shield material throughout BFR’s Super Heavy booster and Starship upper stage. Being forced to deal with a variety of different TPS materials inevitably raises the complexity and cost of a given spacecraft, so being able to significantly reduce the number of materials needed could be a boon for Starship.

NASA and SpaceX’s Space Act Agreement can be found here [PDF].

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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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Investor's Corner

Tesla gets bold Robotaxi prediction from Wall Street firm

Last week, Andrew Percoco took over Tesla analysis for Morgan Stanley from Adam Jonas, who covered the stock for years. Percoco seems to be less optimistic and bullish on Tesla shares, while still being fair and balanced in his analysis.

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Credit: Tesla

Tesla (NASDAQ: TSLA) received a bold Robotaxi prediction from Morgan Stanley, which anticipates a dramatic increase in the size of the company’s autonomous ride-hailing suite in the coming years.

Last week, Andrew Percoco took over Tesla analysis for Morgan Stanley from Adam Jonas, who covered the stock for years. Percoco seems to be less optimistic and bullish on Tesla shares, while still being fair and balanced in his analysis.

Percoco dug into the Robotaxi fleet and its expansion in the coming years in his latest note, released on Tuesday. The firm expects Tesla to increase the Robotaxi fleet size to 1,000 vehicles in 2026. However, that’s small-scale compared to what they expect from Tesla in a decade.

Tesla expands Robotaxi app access once again, this time on a global scale

By 2035, Morgan Stanley believes there will be one million Robotaxis on the road across multiple cities, a major jump and a considerable fleet size. We assume this means the fleet of vehicles Tesla will operate internally, and not including passenger-owned vehicles that could be added through software updates.

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He also listed three specific catalysts that investors should pay attention to, as these will represent the company being on track to achieve its Robotaxi dreams:

  1. Opening Robotaxi to the public without a Safety Monitor. Timing is unclear, but it appears that Tesla is getting closer by the day.
  2. Improvement in safety metrics without the Safety Monitor. Tesla’s ability to improve its safety metrics as it scales miles driven without the Safety Monitor is imperative as it looks to scale in new states and cities in 2026.
  3. Cybercab start of production, targeted for April 2026. Tesla’s Cybercab is a purpose-built vehicle (no steering wheel or pedals, only two seats) that is expected to be produced through its state-of-the-art unboxed manufacturing process, offering further cost reductions and thus accelerating adoption over time.

Robotaxi stands to be one of Tesla’s most significant revenue contributors, especially as the company plans to continue expanding its ride-hailing service across the world in the coming years.

Its current deployment strategy is controlled and conservative to avoid any drastic and potentially program-ruining incidents.

So far, the program, which is active in Austin and the California Bay Area, has been widely successful.

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Tesla Model Y L is gaining momentum in China’s premium segment

This suggests that the addition of the Model Y L to Tesla China’s lineup will not result in a case of cannibalization, but a possible case of “premiumization” instead.

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Credit: Tesla

Tesla’s domestic sales in China held steady in November with around 73,000 units delivered, but a closer look at the Model Y L’s numbers hints at an emerging shift towards pricier variants that could very well be boosting average selling prices and margins. 

This suggests that the addition of the Model Y L to Tesla China’s lineup will not result in a case of cannibalization, but a possible case of “premiumization” instead.

Tesla China’s November domestic numbers

Data from the a Passenger Car Association (CPCA) indicated that Tesla China saw domestic deliveries of about 73,000 vehicles in November 2025. This number included 34,000 standard Model Y units, 26,000 Model 3 units, and 13,000 Model Y L units, as per industry watchers. 

This means that the Model Y L accounted for roughly 27% of Tesla China’s total Model Y sales, despite the variant carrying a ~28% premium over the base RWD Model Y that is estimated to have dominated last year’s mix.

As per industry watcher @TSLAFanMtl, this suggests that Tesla China’s sales have moved towards more premium variants this year. Thus, direct year-over-year sales comparisons might miss the bigger picture. This is true even for the regular Model Y, as another premium trim, the Long Range RWD variant, was also added to the lineup this 2025. 

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November 2025 momentum

While Tesla China’s overall sales this year have seen challenges, the Model Y and Model 3 have remained strong sellers in the country. This is especially impressive as the Model Y and Model 3 are premium-priced vehicles, and they compete in the world’s most competitive electric vehicle market. Tesla China is also yet to roll out the latest capabilities of FSD in China, which means that its vehicles in the country could not tap into their latest capabilities yet. 

Aggregated results from November suggest that the Tesla Model Y took the crown as China’s #1 best-selling SUV during the month, with roughly 34,000 deliveries. With the Model Y L, this number is even higher. The Tesla Model 3 also had a stellar month, seeing 25,700 deliveries during November 2025.

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Cybertruck

Tesla Cybertruck earns IIHS Top Safety Pick+ award

To commemorate the accolade, the official Cybertruck account celebrated the milestone on X.

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Credit: IIHS/YouTube

The Tesla Cybertruck has achieved the Insurance Institute for Highway Safety’s (IIHS) highest honor, earning a Top Safety Pick+ rating for 2025 models built after April 2025. 

The full-size electric pickup truck’s safety rating is partly due to the vehicle’s strong performance in updated crash tests, superior front crash prevention, and effective headlights, among other factors. To commemorate the accolade, the official Cybertruck account celebrated the milestone on X.

Cybertruck’s IIHS rating

As per the IIHS, beginning with 2025 Cybertruck models built after April 2025, changes were made to the front underbody structure and footwell to improve occupant safety in driver-side and passenger-side small overlap front crashes. The moderate overlap front test earned a good rating, and the updated side impact test also received stellar marks.

The Cybertruck’s front crash prevention earned a good rating in pedestrian scenarios, with the standard Collision Avoidance Assist avoiding collisions in day and night tests across child, adult crossing, and parallel paths. Headlights with high-beam assist compensated for limitations, contributing to the top award.

Safest and most autonomous pickup

The Cybertruck is one of only two full-size pickups to receive the IIHS’ Top Safety Pick + rating. It is also the only one equipped with advanced self-driving features via Tesla’s Full Self-Driving (Supervised) system. Thanks to FSD, the Cybertruck can navigate inner city streets and highways on its own with minimal supervision, adding a layer of safety beyond passive crash protection.

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Community reactions poured in, with users praising the vehicle’s safety rating amidst skepticism from critics. Tesla itself highlighted this by starting its X post with a short clip of a Cybertruck critic who predicted that the vehicle will likely not pass safety tests. The only question now is, of course, if the vehicle’s Top Safety Pick+ rating from the IIHS will help the Cybertruck improve its sales. 

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