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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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Tesla Sweden faces new pressure in Sweden as Assa Abloy joins union action

The sympathy strike will block Assa Abloy’s 330 employees across six Swedish facilities from servicing or maintaining locks and gates used at Tesla Sweden’s sites.

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Credit: NicklasNilsso14/X

The labor standoff between Tesla and Sweden’s IF Metall union has widened again, this time pulling in Assa Abloy Industrial, a manufacturer of industrial doors and locks. 

IF Metall announced a new sympathy strike halting all Assa Abloy services for Tesla, set to take effect November 4, according to Dagens Arbete (DA). The move is aimed at further pressuring Tesla into signing a collective agreement after nearly two years of ongoing labor conflict.

New strike targets Tesla’s industrial operations

The sympathy strike will block Assa Abloy’s 330 employees across six Swedish facilities from servicing or maintaining locks and gates used at Tesla Sweden’s sites. IF Metall hopes the measure will disrupt Tesla’s daily operations and highlight the growing solidarity among Swedish companies.

Assa Abloy becomes the latest in a line of firms drawn into the dispute, with the Swedish Mediation Institute now logging fourteen conflict notices since September. The escalation shows that unions and partner industries are aligning to support of IF Metall’s campaign to secure a collective bargaining deal, something Tesla has consistently resisted.

IF Metall says Tesla must understand Sweden’s labor model

IF Metall chair Marie Nilsson recently reiterated her call for Tesla Sweden to reconsider its stance on organized labor, noting that Sweden’s union system differs sharply from the more adversarial model in the United States. 

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“I can certainly understand that Elon Musk and Tesla are skeptical of the trade union movement,” Nilsson said. “They have experience with American unions that operate in a completely different environment and that have to be militant in a different way.”

Nilsson emphasized that Swedish unions function cooperatively and that signing a collective agreement locally does not commit Tesla to similar deals elsewhere. “Let’s give us a chance,” she added. “It is the practical system we have here to regulate the conditions.”

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Elon Musk: Tesla autonomous driving might spread faster than any tech

The CEO noted that “hardware foundations have been laid for such a long time.”

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Credit: Tesla

Elon Musk has shared one of his most optimistic forecasts for Tesla’s self-driving rollout yet. As per the CEO, Tesla’s self-driving system could see the fastest technological adoption in history, thanks to the fleet’s capability to gain autonomous capabilities through a software update.

The CEO shared his forecast in a post on social media platform X.

Tesla’s aims to scale autonomy

Musk’s comment came as a response to industry watcher Sawyer Merritt, who posted a comparison between the geofence of Tesla’s Robotaxi network and Waymo’s service area. As can be seen in the graphic, Tesla’s Austin geofence has gotten noticeably larger compared to Waymo’s service area. 

In his response, Musk stated that “Tesla autonomous driving might spread faster than any technology ever.” He also stated that “hardware foundations have been laid for such a long time,” as a software update could unlock full autonomy “for millions of pre-existing cars in a short period of time.”

Musk’s comment bodes well for Tesla’s Robotaxi ambitions, which seem to be finally in reach with the deployment of Unsupervised FSD in vehicle factories, as well as Austin and the Bay Area. For now, however, Tesla’s Austin Robotaxis and Bay Area ride-hailing vehicles are still operated with a safety monitor in the driver’s seat. 

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Tesla’s latest Austin expansion

Tesla recently expanded its Austin Robotaxi service area this week to 243 square miles, its largest yet and nearly triple the coverage from two months ago. The move outpaces Waymo’s local service footprint, which remains at around 90 square miles.

The expansion marks Tesla’s second major Austin update since August and emphasizes its push to dominate the autonomous ride-hailing landscape. With both Tesla and Waymo racing to prove scale and reliability, Musk’s confidence suggests the real contest may be about who can move fastest once the tech flips on across Tesla’s fleet. Once that happens, Tesla would effectively be able to win the self-driving race. 

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Tesla sends clear message to Waymo with latest Austin Robotaxi move

It is the first expansion Tesla has made in Austin since the one on August 26. The company still operates in the Bay Area of California as well, referring to that program specifically as a “ride-hailing service.”

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Credit: Tesla

Tesla has sent a clear message to Waymo with its latest move to its Robotaxi program in Austin, Texas.

Tesla and Waymo are the two true leaders in autonomous ride-hailing to an extent. Tesla has what many believe is a lot of potential due to its prowess with the Supervised Full Self-Driving suite. It is also operating a driverless Robotaxi service in Austin with a “Safety Monitor” that sits in the passenger’s seat.

Tesla explains why Robotaxis now have safety monitors in the driver’s seat

The two companies have been competing heavily in the market since they both launched driverless ride-hailing services in Austin this year: Waymo’s in March and Tesla’s in June.

One of the main drivers in the competition between the two is service area size, or the geofence in which the cars will operate without a driver. In August, the two were tied with a service area of about 90 square miles (233.099 sq. km).

Tesla then expanded to about 170 square miles (440.298 sq. km) on August 26, dwarfing Waymo’s service area and expanding to freeways. Tesla’s freeway operation of the Robotaxi suite requires the Safety Monitor to be in the driver’s seat for safety reasons.

On Tuesday evening, Tesla made another move that sent a clear message to Waymo, as it expanded once again, this time to 243 square miles (629.367 sq. km).

This is according to Robotracker:

It is the first expansion Tesla has made in Austin since the one on August 26. The company still operates in the Bay Area of California as well, referring to that program specifically as a “ride-hailing service.”

Yesterday, it expanded that service to the San Jose Mineta International Airport, something it has been working on for several months.

Waymo has its own set of distinct advantages over Tesla as well, as it operates in more cities and states than the EV maker. Waymo currently has its autonomous vehicle services in Phoenix, Arizona, San Francisco, Los Angeles, Austin, and Atlanta, Georgia.

Tesla plans to have half of the U.S. population with access to the Robotaxi platform by the end of the year.

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