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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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5 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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Watch Tesla’s FSD tackle water cup challenge, dirt roads in China

How does Tesla’s Full Self-Driving face off against competitors in China when it comes to smoothness and scalability?

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1 hour ago

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March 16, 2025

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Credit: 王船船 | Douyin (via Tesla on X)

Tesla’s Full Self-Driving (FSD) started going out for testing in China last month, representing the first market outside of North America to get the software. Amidst competition in the automated driving space from a number of other Chinese companies, Tesla’s FSD seems to be impressing in early reviews, with recent reviews highlighting both the software’s smoothness and its ability to adapt and perform well on non-traditional roads.

In a Saturday video originally posted by user 王船船 on Douyin, the Chinese version of TikTok, a driver utilizes the Supervised FSD system while performing what’s called the “water challenge,” in which a cup of water is balanced on the driver’s side window ledge to see if driving is smooth enough to avoid spilling.

The drive spans a little more than four minutes, and the system manages to make it through without the water spilling in any substantial quantities. The driver mostly remains on city streets, but you can see a handful of quick, unexpected stops, turns, and other maneuvers that one might expect to make the cup tip completely.

The video was also reposted on X by Tesla’s main account, with the company highlighting the system’s “maximum smoothness” as demonstrated in the video. Tesla VP of AI Ashok Elluswamy also reposted the video, saying in a separate follow-up post that “FSD’s been prepared for this one.”

Although Tesla’s FSD system didn’t have access to real-world driving data from the company’s vehicles at the time of its launch in China, Elon Musk recently explained that the company used publicly available video from the internet to help pre-train FSD for Chinese streets and traffic laws.

In addition to helping with city streets, Tesla has explained in the past that its camera- and video-based FSD neural network training makes the system easily scalable to multiple countries, fringe traffic cases, and even less traditional roads.

As another example of this in China, FSD testers also took to some dirt roads last week, showing just how well the software seems to handle some seemingly-deep and super-narrow back roads. You can see excerpts from this video below, or check out the full 25-minute version from user AE68 on Douyin.

READ MORE ON TESLA CHINA: Cheaper Tesla Model Y may launch in China

Tesla’s FSD in China amidst local competition

Tesla officially launched a localized data privacy version of FSD Supervised in China last month, The launch came amidst a headstart from multiple competitors in the autonomous driving space, including from Chinese automakers Baidu, Huawei, and still others.

The Avatr 11 electric vehicle (EV), a jointly created project from Changan New Energy, CATL, and Huawei, was recently seen being tested by Out of Spec’s Kyle Conner. The system uses Huawei’s latest automated driving system technology, Qiankun ADS 3.2, which Conner recently said was “the best driver assistance he’s ever experienced” in a recent review on his trip to China.

You can see this video and an additional video from Conner and Out of Spec discussing the emerging autonomous vehicle industry in China below. It’s also worth noting that both of these were released just a few weeks before Tesla’s first version of FSD launched in the country.

The Best FSD System In China! 1 Hour Drive Using Huawei Qiankun ADS 3.2 Installed In Avatr 11 (2/1/25)

The EV Industry Isn’t Ready For China’s FSD Breakthrough (2/2/25)

Elon Musk clarifies the holdup with Tesla Full Self-Driving launch in Europe

 

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Elon Musk roasts owners of this car brand after another Tesla vandalism incident

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7 hours ago

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March 16, 2025

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Elon Musk roasted owners of one specific car brand after yet another incident of a Tesla being vandalized, this time in New York.

Tesla owners have had a bit of a target on their backs in recent months as Musk, CEO of the company, has joined forces with U.S. President Donald Trump in an effort to eliminate excessive and unneeded government spending in the new Department of Government Efficiency, or DOGE.

Due to Musk’s bold personality and unfiltered political beliefs, he has gained plenty of critics in the last few months. Tesla owners are being targeted as a result, seeing their vehicles be vandalized on nearly a daily basis.

Tesla-owned showrooms across the country have also been the target of some attacks, as one was even damaged in a series of shootings, another lit on fire by a Molotov cocktail.

Nevertheless, Musk has continued to stand firm on his beliefs, and Tesla drivers are getting fed up with the amount of damage being done to their cars. In this particular instance, someone drew a swastika on the side of a New York City Tesla Cybertruck owner. He was able to confront the person who drew the offensive logo, an exchange that was caught on camera:

The video was shared on X, which grabbed the attention of Musk, who was sure to criticize the make of the assailant’s vehicle: a Subaru.

Musk said:

“Crazy people. Naturally, he drives a Subaru …”

The playful jab at Subaru drivers likely comes from the stereotype that those vehicles are usually driven by people with intense political and social beliefs. Facetious posts on Reddit claim that Subarus won’t operate without at least ten bumper stickers on them. Subaru’s past marketing and advertising campaigns have attracted those who are “outdoorsy,” Google’s AI description of the drivers states.

Musk has never held back and never will. In an interview with MSNBC, he said he will speak his mind and if his companies lose money because of it, “so be it.” One thing is for sure, Musk is not going to shy away from speaking or posting how he pleases.

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Tesla stores continue to face anti-Musk protests

Scenes from a protest outside of Tesla’s store in Loveland, Colorado.

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21 hours ago

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March 15, 2025

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Tesla stores have been the target of widespread protests and vandalism in recent weeks, after Elon Musk made a controversial gesture in January, and as he and the Trump administration’s newly created government efficiency division continues to gut federal agencies.

On Saturday, I went to the Tesla store in Loveland, Colorado, where demonstrators were already protesting upon my arrival at roughly 12:45 p.m. MT.  Walking up to the protest, I could see scattered groups of demonstrators lined up along about two blocks, spanning from the Tesla store to a nearby intersection and Sprouts location. One protestor said he had counted about 230 people at around 1:00 p.m. MT.

The protest felt generally peaceful, with cars driving by and honking, and demonstrators leaving a large space between the front of the Tesla store and the sidewalk, easily allowing workers and customers to go in and out.

You can see a few videos and photos from the site below, along with some of the responses I got from protestors and a prospective customer.

READ MORE ON TESLA PROTESTS AND VANDALISM:

I spoke to about a dozen protestors about what they were protesting against. Most said they were there to condemn Musk’s recent federal worker and program cuts with the Trump administration, his performance of what some said resembled a Nazi salute at Trump’s inauguration ceremony in January, or the administration’s recent attacks against transgender and queer individuals.

One protestor, Elsa, identified as a former Republican and said she was “highly concerned that our Constitution is being ignored,” especially with regards to the three branches of government and the system of checks and balances.

“It surprises me that, even if you voted for Trump, or you believe in capitalism, which, I didn’t vote for Trump, but I do believe in capitalism — I’m a former Republican, I was a Republican for most of my life — but it’s dangerous to have power rest in a handful of ultra-wealthy people,” Elsa said.

“And our whole country needs to realize that,” she adds. “This to me is not even Republican or Democrat at this point.”

Instead, she says it now comes down to whether people want to give billionaires huge tax breaks, or to use that money to support a range of groups in the U.S., including those who have social security benefits, are veterans, or are 9/11 survivors seeking cancer treatments, as a few examples.

Another protestor, Mary, said she was taking part in the demonstration “because she loves this country and democracy,” adding that she wanted to help preserve democracy for her grandchildren.

Still another protestor, Bryan, said that they were protesting because of the Trump administration and Musk’s attempts to erase transgender, non-binary, and queer people from history, drawing comparisons to the rise of fascism in Nazi Germany, where early human rights violations were lodged against gay and queer communities.

“I’m here because I have to be,” Bryan said. “I’m afraid of the future.”

Yet another person and his family were holding Ukraine flags, saying that they were protesting for a wide range of reasons, but especially for Trump’s recent meeting with Ukraine President Volodymyr Zelenskyy and Musk’s claims that the top Ukrainian executive was to blame for what he has called a “forever war.”

While most protestors appeared to be generally friendly, especially with each other, I did hear a few exchanges between demonstrators and those with other opinions. While I heard more cars honking throughout the experience, seemingly in support of the protests, I also noticed a few from which passengers yelled things like “Go Trump.”

“Direct action, we need to stop these fascists with direct action,” one protestor yelled in response.

Additionally, I also talked to a prospective customer, Kristy, who was there for a test drive and said she had a negative experience with the protestors.

“I was test driving a Tesla, and as we pulled in and parked right here, this black one, these people right here in the middle yelled at me, ‘Hope you’re turning in your f*cking Nazi car,’ and I said ‘F*ck you,’” Kristy explained.

“And they’re like ‘F*ck you too, you’re a Nazi, f*cking Nazi lovers.’ And so, they’re just yelling racial slurs at me, and I’m far from a Nazi.”

Tesla store advisers declined to comment on the protests, and so did Loveland police.

Other Saturday protest footage from Tesla stores in California, Texas, and New York

The Loveland Tesla store has also been the site of repeated attacks in recent weeks, with authorities on Friday making a second arrest following multiple incidents. You can see the Department’s press release for the arrest below.

The protest was also part of widespread demonstrations on Saturday, and it’s just the latest in actions targeting Musk’s electric vehicle (EV) company, some of which have included acts of vandalism, graffiti, arson, and even the use of weapons on Tesla storefronts.

Multiple other protests were also captured in footage on Saturday, including one in Santa Rosa, California, as shared by the San Francisco Chronicle, and another attended by conspiracy theorist Alex Jones in Austin, Texas. Still another was captured in New York City, and you can see footage from each of these protests below.

Tesla vandalism cases under investigation by FBI Seattle

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