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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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Elon Musk just roasted Sam Altman’s Tesla Roadster cancellation

“And you forgot to mention act 4, where this issue was fixed and you received a refund within 24 hours.

But that is in your nature.”

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Elon Musk has responded to OpenAI CEO Sam Altman’s decision to cancel his Tesla Roadster reservation, which he revealed on X on Thursday.

We reported on Altman’s decision, which he called “A tale in three acts,” showing his confirmation email from Tesla back in 2018, an email requesting his $50,000 deposit back after canceling his order, and a notification from Google that the email he sent was not delivered.

Musk did not take too kindly to the post from his tech rival, first referencing his position with OpenAI, and then confirming that Altman received his reservation deposit back within 24 hours:

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OpenAI was started by Musk, Altman, and others back in 2015, and was geared toward being a non-profit company that would develop safe artificial intelligence that would be accessible to people.

However, Musk and Altman did not agree on the future of the company. Musk left, and Altman turned OpenAI into a for-profit company. This led to a variety of lawsuits and some very public spats between the two. Musk has called out Altman for turning the company into a for-profit, which has been his main source of criticism for his former colleague.

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The Roadster has been hanging in the balance of Tesla’s manufacturing plans for seven years, but the company has made more indications that it will be unveiled later this year and will have some insane technologies.

Musk said on Friday in an episode of the Joe Rogan Experience Podcast that Tesla is “getting close to demonstrating the prototype.”

He said:

“Whether it’s good or bad, it will be unforgettable. My friend Peter Thiel once reflected that the future was supposed to have flying cars, but we don’t have flying cars. I think if Peter wants a flying car, he should be able to buy one…I think it has a shot at being the most memorable product unveil ever. [It will be unveiled] hopefully before the end of the year. You know, we need to make sure that it works. This is some crazy technology in this car. Let’s just put it this way: if you took all the James Bond cars and combined them, it’s crazier than that.”

Musk hinted that the vehicle could fly and would have “crazy technology” that would put James Bond’s vehicles to shame. It will be interesting to see what Tesla will unveil when the event happens and if it can come through on this mind-blowing teaser.

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SpaceX successfully launches 100th Starlink mission of 2025

With 100 Starlink missions completed for 2025, space enthusiasts have noted that SpaceX has successfully launched 2,554 Starlink satellites so far this year.

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(Credit: Starlink)

SpaceX achieved its 100th Starlink mission of the year on Friday, October 31, marking another milestone for 2025. 

A Falcon 9 rocket carrying 28 Starlink broadband satellites successfully lifted off from Vandenberg Space Force Base in California at 4:41 p.m. ET, carrying another 28 Starlink satellites to Low Earth Orbit (LEO).

Falcon 9 booster’s 29th flight

Roughly 8.5 minutes after liftoff, the Falcon 9’s first stage touched down on the drone ship Of Course I Still Love You in the Pacific Ocean. This marked the booster’s 29th flight, which is approaching SpaceX’s reuse record of 31 missions.

This latest mission adds to SpaceX’s impressive 138 Falcon 9 launches in 2025, 99 of which were dedicated to Starlink, according to Space.com. The company’s focus on reusing boosters has enabled this breakneck pace, with multiple launches each week supporting both Starlink’s expansion and external customers.

Starlink’s network continues massive global expansion

Starlink remains the largest active satellite constellation in history, with more than 10,000 satellites launched, nearly 8,800 of which are currently active. SpaceX recently achieved Starlink’s 10,000-satellite milestone. With 100 Starlink missions completed for 2025, space enthusiasts have noted that SpaceX has successfully launched 2,554 Starlink satellites so far this year.

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Starlink, which provides high-speed, low-latency internet connectivity even to the world’s most remote areas, has been proven to be life-changing technology for people across the globe. The service is currently operational in about 150 countries, and it currently has over 5 million subscribers worldwide. From this number, 2.7 million joined over the past year.

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Tesla shares updated timeframe for Cybertruck FSD V14 release

The Cybertruck was expected to receive FSD V14 before the end of the month, but Tesla was not able to meet the target.

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Credit: Tesla

Tesla’s Full Self-Driving (FSD) V14 update for the Cybertruck could arrive this weekend, as per recent comments from Director of Autopilot Software and VP of AI Ashok Elluswamy. 

The Cybertruck was expected to receive FSD V14 before the end of the month, but Tesla was not able to meet the target.

Cybertruck FSD V14

Considering the extended wait for FSD V14, it was no surprise that several Cybertruck owners were asking for updates about the system’s rollout to the all-electric pickup truck on Friday. These included the official Cybertruck X account, which responded to Elluswamy’s end of month estimate with “I only see trick. Where is my treat.” 

This prompted a response from the AI executive, who replied with, “Sorry, pushing for early access Cyber release over the weekend.” This means that if all goes well, Cybertruck owners would be able to experience FSD V14 very soon. Some, however, are wondering if Tesla would go straight to V14.2 for the Cybertruck’s FSD V14 update, or if the vehicle will receive V14.1 first. 

Tesla pushes to unify FSD experience across its lineup

The upcoming Cybertruck rollout represents the next step in Tesla’s efforts to roll out FSD capabilities across all of its vehicles. FSD V14 is a notable step forward for the company’s AI-driven self driving system, with features like Mad Max mode getting positive reviews from longtime Full Self Driving testers.

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For the Cybertruck, the FSD V14 update would mark one of its first major over-the-air upgrades for the vehicle. Likely due to its size, the Cybertruck tends to receive FSD updates later than the S3XY lineup, which is quite surprising considering that the all-electric pickup truck is a premium-priced vehicle that is home to some of Tesla’s most advanced technologies.

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