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SpaceX's next Starship rapidly coming together as Elon Musk shares latest progress

SpaceX CEO Elon Musk has offered the first official glimpse of a rarely-seen part of Starship production. (NASASpaceflight/bocachicagal, Elon Musk)

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SpaceX CEO Elon Musk has shown off a rarely-seen phase of Starship construction, further confirming that the next full-scale rocket ship is rapidly coming together after operator error destroyed its predecessor on April 3rd.

Around 5 am local time (10:00 UTC) on April 5th, Musk shared a photo of a smaller secondary tank’s installation inside Starship SN4’s full-size liquid methane tank. The photo is the first time SpaceX or its CEO has offered a glimpse inside this lesser-known part of Starship production and assembly and simultaneously offers insight into a design that’s been a mystery for months. Over the last few weeks, local residents-turned-unofficial-SpaceX-photographers have captured several photos of an internal Starship header tank design far removed from the nosecone tank Musk has previously discussed.

Those header tanks are a necessity to enable Starship’s ability to quickly, reliably, and safely reignite its Raptor engines for recovery and landing-related burns. For a ship like Starship SN4, those header tanks are a sign that SpaceX may want to use the ship to perform Starship’s most crucial test short of orbit — a ~20 km (12.5 mi) flight test meant to demonstrate a skydiver-style landing maneuver. While that skydiver landing test remains several consecutive milestones distant, Musk’s April 5th photo confirms that Starship SN4 is making significant progress towards final assembly.

SpaceX has begun final work on one of Starship SN4’s three tank domes. Several more sections are also in the late stages of assembly. (NASASpaceflight – bocachicagal, 04/05/2020)

Known as header tanks, SpaceX’s large Starship launch vehicle upper stage and orbital spacecraft requires smaller, secondary tanks aside from the main liquid oxygen and methane propellant tanks that make up the bulk of its body. In these early stages of prototype development, those tanks serve one main purpose: reserve a small portion of pressurized propellant for Starship landing burns.

While Starship’s main tanks still need to be pressurized at all times to ensure the rocket’s structural integrity, smaller header tanks make it much easier to safely feed Raptor engines fuel during even the most chaotic of aerial maneuvers. For rocket engines, even the slightest introduction of pressurization gas or voids into the combustion process can lead to immediate destruction — a bit like how a tiny air bubble can be almost instantly fatal for humans. Starship header tanks thus ensure that only a fraction of the overall tank volume is in play during the ship’s most critical maneuvers.

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The late Starship SN1’s liquid oxygen header tank is pictured here in January 2020. (Elon Musk)
Similar but different, Starship SN4’s liquid methane header tank installation is shown before and during installation. (NASASpaceflight – bocachicagal, Elon Musk)

Requiring both a fuel and oxidizer, Starships thus need two header tanks. Currently, Starship’s design places the liquid methane header tank directly inside the main methane tank itself. The liquid oxygen header tank, however, is situated in the very tip of Starship’s nose section, a location chosen to optimize the vehicle’s center of gravity for stability during a radical skydiver-style landing maneuver.

Musk’s April 5th photo and caption revealed that SpaceX began installing Starship SN4’s methane header tank just an hour or two after it had flipped the ship’s partially-completed liquid methane tank dome. Thanks to SpaceX’s more efficient use of a common dome design in their Falcon and Starship rockets, that dome also serves as the upper dome of the ship’s larger liquid oxygen tank. After the methane header tank is installed, a funnel-like sump will be the last addition needed to finish the section.

Workers use a rotating jig to flip Starship SN4’s common liquid oxygen and methane tank dome on April 5th. (NASASpaceflight – bocachicagal)

With the majority of Starship SN4 already in work around SpaceX’s Boca Chica, Texas rocket factory, the ship could be just a week or less away from kicking off the stacking phase of assembly. Stay tuned!

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 puts Giga Berlin in Plaid Mode with new massive investment

The facility, Tesla’s first in Europe, opened in 2022 and has become a cornerstone for Model Y production and, increasingly, in-house battery manufacturing. Recent announcements highlight a dual focus on scaling vehicle output and advancing vertical integration through 4680 battery cells.

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Credit: Tesla

Tesla is pushing forward with significant upgrades at its Gigafactory Berlin-Brandenburg in Grünheide, Germany, signaling renewed confidence in its European operations despite past market challenges.

The facility, Tesla’s first in Europe, opened in 2022 and has become a cornerstone for Model Y production and, increasingly, in-house battery manufacturing. Recent announcements highlight a dual focus on scaling vehicle output and advancing vertical integration through 4680 battery cells.

In April, plant manager André Thierig announced a 20 percent increase in Model Y production starting in July, following a record Q1 output of more than 61,000 vehicles. To support the ramp-up, Tesla plans to hire approximately 1,000 new employees beginning in May and convert 500 temporary workers to permanent positions.

The move is expected to lift weekly production significantly, addressing rebounding demand in Europe after a challenging 2025.

The expansion builds on earlier progress. In 2025, Tesla secured partial approvals to add roughly 2 million square feet of factory space, raising potential annual vehicle capacity from around 500,000 toward 800,000 units, with longer-term ambitions approaching one million vehicles per year. Logistical improvements, new infrastructure, and battery-related facilities are already underway on company-owned land.

Battery production is the latest major focus. On May 12, Thierig revealed an additional $250 million investment in the on-site cell factory. This more than doubles the planned 4680 battery cell capacity to 18 gigawatt-hours annually—up from the 8 GWh target set in December 2025—while creating over 1,500 new battery-related jobs.

Total cell investments at the site now exceed previous figures, bringing the factory closer to full vertical integration: cells, packs, and vehicles produced under one roof. Tesla describes this as unique in Europe and a step toward stronger supply chain resilience.

The plans come amid regulatory and community hurdles. Earlier expansion proposals faced protests over environmental concerns and water usage, leading to phased approvals beginning in 2024. Tesla has navigated these by emphasizing sustainable practices and economic benefits, including thousands of local jobs in Brandenburg.

With nearly 12,000 employees already on site and production steadily climbing, Gigafactory Berlin is poised for growth. The combined vehicle and battery expansions position the plant as a key hub for Tesla’s European ambitions, potentially making it one of the continent’s largest manufacturing complexes if local support continues.

As EV demand recovers, these investments underscore Tesla’s commitment to scaling efficiently in Germany while addressing regional supply chain needs.

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Honda gives up on all-EV future: ‘Not realistic’

Mibe believes the demand for its gas vehicles is certainly strong enough and has changed “beyond expectations.” As many drivers went for EVs a few years back, hybrids are becoming more popular for consumers as they offer the best of both worlds.

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honda logo with red paint
Ivan Radic, CC BY 2.0 , via Wikimedia Commons

Honda has given up on a previous plan to completely changeover to EVs by 2040, a new report states. The company’s CEO, Toshihiro Mibe, said that the idea is “not realistic.”

Mibe believes the demand for its gas vehicles is certainly strong enough and has changed “beyond expectations.” As many drivers went for EVs a few years back, hybrids are becoming more popular for consumers as they offer the best of both worlds.

Mibe said (via Motor1):

“Because of the uncertainty in the business environment and also the customer demand, is changing beyond our expectation and, therefore, we have judged that it’ll be difficult to achieve. That ratio [100-percent electric in 2040] is not realistic as of now. We have withdrawn this target.”

Instead of going all-electric, Honda still wants to oblige by its hopes to be net carbon neutral by 2050. It will do this by focusing on those popular hybrid powertrains, planning to launch 15 of them by March 2030.

Honda will invest 4.4 trillion yen, or almost $28 billion, to build hybrid powertrains built around four and six-cylinder gas engines.

There are so many companies abandoning their all-electric ambitions or even slowing their roll on building them so quickly. Ford, General Motors, Mercedes, and Nissan have all retreated from aggressive EV targets by either cancelling, delaying, or pausing the development of electric models.

Hyundai’s 2030 targets rely on mixed offerings of electric, hybrid & hydrogen vehicles

Early-decade pledges from multiple brands proved overly ambitious as infrastructure lags, battery costs remain high in some markets, and many buyers prefer hybrids for their convenience and range. Toyota has long championed hybrids, while others have quietly extended internal-combustion timelines.

For Honda—historically known for reliable gasoline engines—this shift leverages its core strengths while buying time to refine electric technology. Whether the hybrid-heavy strategy will protect market share in an increasingly competitive landscape remains to be seen, but one thing is clear: the gas engine is far from dead at Honda, unfortunately.

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Delta Airlines rejects Starlink, and the reason will probably shock you

In a pointed exchange on X, Elon Musk defended SpaceX’s uncompromising approach to Starlink’s in-flight internet service, explaining why Delta Air Lines walked away from a deal.

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Delta Airlines Airbus photographed April 2024 Delta-owned. No expiration date, unrestricted use.

SpaceX frontman Elon Musk explained on Wednesday why commercial airline Delta got cold feet over offering Starlink for stable internet on its flights — and the reason will probably shock you.

In a pointed exchange on X, Elon Musk defended SpaceX’s uncompromising approach to Starlink’s in-flight internet service, explaining why Delta Air Lines walked away from a deal.

Delta rejected Starlink because it insisted on routing all connectivity through its branded “Delta Sync” portal rather than allowing a simple Starlink experience.

Instead, the airline partnered with Amazon’s Project Kuiper—rebranded as Amazon Leo—for high-speed Wi-Fi on up to 500 aircraft, with rollout targeted for 2028. At the time of the announcement, Kuiper had roughly 300 satellites in orbit, while Starlink operated more than 10,400.

The use of the “Delta Sync” portal would not work for SpaceX, as Musk went on to say that:

“SpaceX requires that there be no annoying ‘portal’ to use Starlink. Starlink WiFi must just work effortlessly every time, as though you were at home. Delta wanted to make it painful, difficult and expensive for their customers. Hard to see how that is a winning strategy.”

Musk doubled down in a follow-up post:

“Yes, SpaceX deliberately accepted lower revenue deals with airlines in exchange for making Starlink super easy to use and available to all passengers.”

SpaceX has structured its airline agreements to prioritize zero-friction access—no captive portals, no SkyMiles logins, no paywalls or ads blocking basic connectivity.

While this means forgoing higher-margin deals that would let carriers monetize the service more aggressively, it ensures Starlink feels like home broadband at 35,000 feet. Passengers on partner airlines such as United, Qatar Airways, and Air France have already praised the service for enabling seamless video calls, streaming, and work mid-flight without interruptions.

Delta’s choice reflects a different philosophy. By keeping Wi-Fi behind its Delta Sync ecosystem, the airline aims to drive loyalty program engagement and control the digital passenger journey. Yet, critics argue this short-term control comes at the expense of immediate competitiveness.

Airlines already installing Starlink are pulling ahead in customer satisfaction surveys, while Delta passengers face years of reliance on slower, legacy systems until Leo launches.

SpaceX’s decision to trade revenue for simplicity will pay off in the longer term, as Starlink is already positioning itself as the default high-speed option for carriers that value passenger satisfaction over incremental fees.

Musk’s focus on creating not only a great service but also a reasonable user experience highlights SpaceX’s prowess with Starlink as it continues to expand across new partners and regions.

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