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SpaceX prepares new Starship tank for explosive test after rapid construction

SpaceX is preparing for a potentially explosive Starship testing, this time featuring the unusual mini-tank pictured here on January 9th. (NASASpaceflight - bocachicagal)

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6 years ago

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Over the last few weeks, SpaceX’s South Texas Starship team has been making progress at a pace unprecedented even for the famously agile rocket company and is moving full speed ahead to kick off a new series of explosive tests as early as this morning.

Ever since SpaceX’s original Starship Mk1 prototype spectacularly failed during a November 2019 pressure test, the company has been rapidly rearranging and modifying the development schedule for its next-generation full-reusable rocket. Be it a side effect or coincidence, SpaceX effectively began closing its Florida Starship factory a week after Mk1’s demise and even shipped some of its Florida-built Starship hardware to Texas in recent weeks. However, most of the Florida workforce (up to 80%) was reportedly redirected elsewhere in the company, avoiding layoffs.

Some portion may have even moved to Texas and joined SpaceX’s Starship Boca Chica facilities. Given just how aggressively SpaceX has been expanding its local facilities and preparing new hardware for the next round of improved Starship prototypes, it seems quite likely that the South Texas outpost did indeed receive an influx of skilled workers. Most recently, the company has demonstrated its rapidly growing expertise in the bizarre art of building steel rockets en plein air by fabricating and integrating new tank domes and steel rings and then shipping the curious contraption to its nearby launch site in a matter of weeks from start to finish.

Although it’s difficult to determine the chronology of every single part of the mysterious new tank, it’s fairly safe to say that work on its structure began less than a week before SpaceX CEO Elon Musk tweeted a surprise update, indicating on December 27th that he was in Boca Chica, Texas working all night on “Starship tank dome production”.

In simple terms, the business half of SpaceX’s next-generation Starship upper stage and Super Heavy boosters are comprised of three main parts, shared by almost all launch vehicles. Both are rocket stages that must be as light as physically possible while supporting thousands of tons worth of supercool liquid oxygen and methane propellant. The majority of a simple rocket is ultimately a duo of cylindrical tanks capped by tank domes – also known as bulkheads. The bottom bulkhead of boosters and upper stages also serves as a mounting point for an engine section, where the vehicle’s rocket engines are attached to the rocket body in order to transfer their thrust throughout the rest of the structure.

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SpaceX CEO Elon Musk says that Starship tank domes have turned out to be “the most difficult part of [the rocket’s] primary structure” to manufacture, thus explaining why he was apparently assisting the Boca Chica team all night on December 27th.

Starship Mk1 exploded on November 20th, 2019 during a nonflammable propellant loading test, a failure that unofficial videos have compellingly linked to the weld joint connecting the rocket’s upper tank dome to its cylindrical tank. That section of the rocket began leaking cryogenic propellant moments before the entire upper dome tore off the rest of the vehicle and launched hundreds of feet into the air.

All hail Baby Tank

In an apparent response to the unsatisfactory results of Starship Mk1’s manufacturing methods, SpaceX has rapidly initiated an already-planned upgrade of its Starship facilities and manufacturing methods in South Texas, taking delivery of a wealth of new tools over the last several weeks. Most recently, SpaceX’s latest step towards demonstrating that it has substantially improved manufacturing quality arrived in the form of a single propellant tank – the same diameter as Starship Mk1 but much shorter than any possible flight hardware.

Quickly nicknamed Bopper (short for Baby Starhopper) by locals and close followers, the miniature Starship test article came together at a truly spectacular pace. Comprised of two single-weld steel rings and two brand new tank domes, it appears that all four of the components were nothing more than parts and steel stock less than three weeks ago. The first sign of activity came around December 19th, when technicians began placing pressed steel sections onto a bulkhead (dome) assembly jig – used to precisely hold the pieces in the right shape and place as they are welded together.

A number of new single-weld steel rings were produced in Texas in the final weeks of 2019, pictured here on December 19th. (NASASpaceflight – bocachicagal)
SpaceX technicians also began assembling the first of two Starship test tank (‘Bopper’) domes around December 19th. (NASASpaceflight – bocachicagal)
Perhaps just 20 days or less after work started on the baby Starship tank, SpaceX transported the new hardware – made up of two domes and two rings – to a nearby launch (and test) pad. (NASASpaceflight – bocachicagal)

Incredibly, aside from taking less than three weeks to go from miscellaneous parts to an assembled Starship tank delivered to the test site, SpaceX technicians appeared to finish stacking and welding its two halves (each a ring and a dome) perhaps a handful of hours before it was lifted onto a transporter and driven to the launch pad.

As of dawn, January 9th, the welds joining the two halves of the mini Starship tank were visibly incomplete and in-progress. Note the bright point and unfinished line near the center, indicative of active welding. (NASASpaceflight – bocachicagal)

Even for SpaceX, moving a prototype from factory to test site hours after its primary structure was welded together represents an almost unfathomably fast pace of work – truly unfathomable in traditional aerospace. Whether or not such a pace of work is smart, sustainable, or worth it remains to be seen, but SpaceX is nevertheless on track to pressure test its new mini Starship tank as early as this morning, potentially resulting in another spectacular overpressure event (i.e. explosion).

If the tank survives up to or beyond the pressures SpaceX has designed it to, it’s safe to say that the next full-scale Starship prototype could come together far sooner than almost anyone might have expected.

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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 Supercharger Diner food menu gets a sneak peek as construction closes out

What are you ordering at the Tesla Diner?

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10 hours ago

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July 18, 2025

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Credit: BradGoldbergMD | X

The Tesla Supercharger Diner in Los Angeles is nearing completion as construction appears to be winding down significantly. However, the more minor details, such as what the company will serve at its 50s-style diner for food, are starting to be revealed.

Tesla’s Supercharger Diner is set to open soon, seven years after CEO Elon Musk first drafted the idea in a post on X in 2018. Musk has largely come through on most of what he envisioned for the project: the diner, the massive movie screens, and the intended vibe are all present, thanks to the aerial and ground footage shared on social media.

We already know the Diner will be open 24/7, based on decals placed on the front door of the restaurant that were shared earlier this week. We assume that Tesla Optimus will come into play for these long and uninterrupted hours.

The Tesla Diner is basically finished—here’s what it looks like

As far as the food, Tesla does have an email also printed on the front door of the Diner, but we did not receive any response back (yet) about what cuisine it will be offering. We figured it would be nothing fancy and it would be typical diner staples: burgers, fries, wings, milkshakes, etc.

According to pictures taken by @Tesla_lighting_, which were shared by Not a Tesla App, the food will be just that: quick and affordable meals that diners do well. It’s nothing crazy, just typical staples you’d find at any diner, just with a Tesla twist:

As the food menu is finalized, we will be sure to share any details Tesla provides, including a full list of what will be served and its prices.

Additionally, the entire property appears to be nearing its final construction stages, and it seems it may even be nearing completion. The movie screens are already up and showing videos of things like SpaceX launches.

There are many cars already using the Superchargers at the restaurant, and employees inside the facility look to be putting the finishing touches on the interior.

It’s almost reminiscent of a Tesla version of a Buc-ee’s, a southern staple convenience store that offers much more than a traditional gas station. Of course, Tesla’s version is futuristic and more catered to the company’s image, but the idea is the same.

It’s a one-stop shop for anything you’d need to recharge as a Tesla owner. Los Angeles building permits have not yet revealed the date for the restaurant’s initial operation, but Tesla may have its eye on a target date that will likely be announced during next week’s Earnings Call.

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News

Tesla’s longer Model Y did not scale back requests for this vehicle type from fans

Tesla fans are happy with the new Model Y, but they’re still vocal about the need for something else.

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1 day ago

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July 17, 2025

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Credit: AlwinArt/Twitter

Tesla launched a slightly longer version of the Model Y all-electric crossover in China, and with it being extremely likely that the vehicle will make its way to other markets, including the United States, fans are still looking for something more.

The new Model Y L in China boasts a slightly larger wheelbase than its original version, giving slightly more interior room with a sixth seat, thanks to a third row.

Tesla exec hints at useful and potentially killer Model Y L feature

Tesla has said throughout the past year that it would focus on developing its affordable, compact models, which were set to begin production in the first half of the year. The company has not indicated whether it met that timeline or not, but many are hoping to see unveilings of those designs potentially during the Q3 earnings call.

However, the modifications to the Model Y, which have not yet been officially announced for any markets outside of China, still don’t seem to be what owners and fans are looking forward to. Instead, they are hoping for something larger.

A few months ago, I reported on the overall consensus within the Tesla community that the company needs a full-size SUV, minivan, or even a cargo van that would be ideal for camping or business use.

Tesla is missing one type of vehicle in its lineup and fans want it fast

That mentality still seems very present amongst fans and owners, who state that a full-size SUV with enough seating for a larger family, more capability in terms of cargo space for camping or business operation, and something to compete with gas cars like the Chevrolet Tahoe, Ford Expedition, or electric ones like the Volkswagen ID.BUZZ.

We asked the question on X, and Tesla fans were nearly unanimously in support of a larger SUV or minivan-type vehicle for the company’s lineup:

Here’s what some of the respondents said:

Tesla is certainly aware that many of its owners would like the company to develop something larger that competes with the large SUVs on the market.

However, it has not stated that anything like that is in the current plans for future vehicles, as it has made a concerted effort to develop Robotaxi alongside the affordable, compact models that it claims are in development.

It has already unveiled the Robovan, a people-mover that can seat up to 20 passengers in a lounge-like interior.

The Robovan will be completely driverless, so it’s unlikely we will see it before the release of a fully autonomous Full Self-Driving suite from Tesla.

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Energy

Tesla launches first Virtual Power Plant in UK – get paid to use solar

Tesla has launched its first-ever Virtual Power Plant program in the United Kingdom.

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1 day ago

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July 17, 2025

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Credit: Tesla Energy | X

Tesla has launched its first-ever Virtual Power Plant program in the United Kingdom. This feature enables users of solar panels and energy storage systems to sell their excess energy back to the grid.

Tesla is utilizing Octopus Energy, a British renewable energy company that operates in multiple markets, including the UK, France, Germany, Italy, Spain, Australia, Japan, New Zealand, and the United States, as the provider for the VPP launch in the region.

The company states that those who enroll in the program can earn up to £300 per month.

Tesla has operated several VPP programs worldwide, most notably in California, Texas, Connecticut, and the U.S. territory of Puerto Rico. This is not the first time Tesla has operated a VPP outside the United States, as there are programs in Australia, Japan, and New Zealand.

This is its first in the UK:

Tesla is not the only company that is working with Octopus Energy in the UK for the VPP, as it joins SolarEdge, GivEnergy, and Enphase as other companies that utilize the Octopus platform for their project operations.

It has been six years since Tesla launched its first VPP, as it started its first in Australia back in 2019. In 2024, Tesla paid out over $10 million to those participating in the program.

Tesla VPP program in California hits new capacity milestone

Participating in the VPP program that Tesla offers not only provides enrolled individuals with the opportunity to earn money, but it also contributes to grid stabilization by supporting local energy grids.

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