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SpaceX’s first orbital Starship begins assembly as steel heat shield passes tests

CEO Elon Musk posted a video of SpaceX engineers testing a small section of a Starship heat shield prototype. (Elon Musk/SpaceX)

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SpaceX CEO Elon Musk says that the company’s South Texas workforce has already begun to fabricate the first orbital-class Starship prototype, while Hawthorne engineers and technicians are in the midst of performing small-scale testing of the vehicle’s unprecedented stainless steel heat shield.

To be assembled out of hexagonal tiles of (presumably) stainless steel, Starship’s metallic heat shield will be one of the most crucial aspects of the orbital spacecraft, particularly with respect to ensuring that it’s extraordinarily easy to reuse. To survive extreme interplanetary-velocity reentry conditions at Mars, Earth, and beyond and remain in a functional, flight-ready condition after landing, SpaceX will need to implement the world’s first orbital-class, large-scale metallic heat shield with an immature technology known as transpirational cooling.

By quite literally drilling tiny holes (pores) into heat shield plates at the hottest parts of Starship’s hull, transpirational cooling effectively allows a large portion of the heat of reentry to be wicked away by the flash evaporation of a liquid, typically water. For SpaceX’s Starship, it’s likely that the coolant of choice would be either liquid water or liquid methane, the former of which offers better cooling per unit of mass at the cost of added plumbing complexity and spaceship mass, while the latter would make use of the same propellant fueling the ship at the cost of worse cooling per unit of mass. Either way, SpaceX will be heading into unproven territory, demanding extensive ground and flight testing to first ensure that the concept is truly viable and then to verify that it can be made as reliable and reusable as it simply has to be.

Tests like those shown on March 17th by Musk indicate that SpaceX is indeed deep into the process of extensive and often destructive testing, something the company has proven to be exceptionally good at. It’s unclear if the above test of Starship’s hexagonal heat shield tiles – likely made out of a variant of 300-series stainless steel – involved tiles with active or passive cooling, but Musk suggested that the hot-spots created with spin-forming torches reached temperatures as high as 1650 Kelvin (2500ºF/1400ºC. Unlike the ablative heat shields SpaceX is familiar with building and operating through its Crew and Cargo Dragon spacecraft, a stainless steel heat shield would be expected to almost entirely resist erosion (i.e. ablation) during extremely high-velocity reentries of at least 12-14 km/s (~31,000 mph, Mach 40+).

Meanwhile, Musk also confirmed that SpaceX has decided to skip constructing a replacement nosecone/fairing for Starhopper, a functional Starship prototype that will be used to conduct extremely short hop tests like Falcon 9’s development-era Grasshopper and F9R test articles. Over the last several weeks, SpaceX technicians have been rapidly assembling what was initially assumed to be the replacement fairing Musk had previously suggested would be built. Instead, the duo of stainless steel barrel sections – relying on steel much thinner than the heavy-duty stuff used to build Starhopper – are apparently the beginnings of the first orbital-class Starship prototype, said by Musk to be aiming for flight-readiness as early as June 2019 around two months ago.

While still an extraordinarily ambitious target for a vehicle that has yet to conduct any integrated hops or flight-tests in any form, the fact that SpaceX is began the process of building the first orbital Starship in late February could actually give the company’s engineers and technicians a fighting chance to complete Starhopper testing and Starship assembly over the next 90-100 days.

If stacked atop each other, the two new steel sections in work would likely stretch a solid 20-30 meters (65-100 ft) tall. Meanwhile, the first orbital-grade tank domes and/or conical nose section is also in the process of being welded together out of smaller segments, already fast approaching something ready to be installed inside the steel barrel sections.

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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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SpaceX to debut new Dragon capsule in Axiom Space launch

Ax-4’s launch marks the debut of SpaceX’s latest Crew Dragon and pushes Axiom closer to building its own space station.

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(Credit: SpaceX)

Axiom Space’s Ax-4 mission targets the International Space Station (ISS) with a new SpaceX Crew Dragon capsule.

The Axiom team will launch a new SpaceX Dragon capsule atop a Falcon 9 rocket from NASA’s Kennedy Space Center in Florida on Wednesday at 8:00 a.m. EDT (1200 GMT). The Ax-4 mission launch was initially set for Tuesday, June 10, but was delayed by one day due to expected high winds.

As Axiom Space’s fourth crewed mission to the ISS, Ax-4 marks the debut of an updated SpaceX Crew Dragon capsule. “This is the first flight for this Dragon capsule, and it’s carrying an international crew—a perfect debut. We’ve upgraded storage, propulsion components, and the seat lash design for improved reliability and reuse,” said William Gerstenmaier, SpaceX’s vice president of build and flight reliability.

Axiom Space is a Houston-based private space infrastructure company. It has been launching private astronauts to the ISS for research and training since 2022, building expertise for its future station. With NASA planning to decommission the ISS by 2030, Axiom has laid the groundwork for the Axiom Station, the world’s first commercial space station. The company has already begun construction on its ISS replacement.

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The Ax-4 mission’s research, spanning biological, life, and material sciences and Earth observation, will support this ambitious goal. Contributions from 31 countries underscore the mission’s global scope. The four-person crew will launch from Launch Complex 39A, embarking on a 14-day mission to conduct approximately 60 scientific studies.

“The AX-4 crew represents the very best of international collaboration, dedication, and human potential. Over the past 10 months, these astronauts have trained with focus and determination, each of them exceeding the required thresholds to ensure mission safety, scientific rigor, and operational excellence,” said Allen Flynt, Axiom Space’s chief of mission services.

The Ax-4 mission highlights Axiom’s commitment to advancing commercial space exploration. By leveraging SpaceX’s Dragon capsule and conducting diverse scientific experiments, Axiom is paving the way for its Axiom Station. This mission not only strengthens international collaborations but also positions Axiom as a leader in the evolving landscape of private space infrastructure.

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SpaceX

SpaceX Dragon to carry Axiom’s Ax-4 crew for ISS research

On June 10, Axiom’s Ax-4 mission heads to the ISS on a SpaceX Dragon capsule. It’s a historic return to space for India, Poland & Hungary.

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(Credit: SpaceX)

Axiom Space’s Ax-4 mission, launched on a SpaceX Dragon spacecraft, will carry a historic international crew to the International Space Station (ISS) next Tuesday, June 10, from NASA’s Kennedy Space Center in Florida.

SpaceX’s Dragon capsule was recently photographed preparing for the Ax-4 launch. The Dragon will dock at the ISS on June 11 at approximately 12:30 p.m. ET for a 14-day mission focused on groundbreaking microgravity research.

The Ax-4 crew will be led by Commander Peggy Whitson from the United States. It includes Pilot Shubhanshu Shukla from India and mission specialists Sławosz Uznański-Wiśniewski from Poland and the European Space Agency and Tibor Kapu from Hungary. This mission marks a historic return to human spaceflight for India, Poland, and Hungary as each nation sends its first government-sponsored astronauts in over 40 years.

“With a culturally diverse crew, we are not only advancing scientific knowledge but also fostering international collaboration. Our previous missions set the stage, and with Ax-4, we ascend even higher, bringing more nations to low-Earth orbit and expanding humanity’s reach among the stars,” Whitson noted.

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The Ax-4 mission’s research portfolio will be Axiom’s most extensive. It includes 60 scientific studies from 31 countries, including the U.S., India, Poland, Hungary, Saudi Arabia, Brazil, Nigeria, the UAE, and Europe. These studies will advance knowledge in human research, Earth observation, life, and biological and material sciences. Key investigations include supporting astronauts with insulin-dependent diabetes, examining microgravity’s impact on the brain, and studying cancer growth, particularly triple-negative breast cancer. Additional research will explore blood stem cells, joint health, blood flow, and astronaut readiness using wearable devices, iPhone software, and AWS Snowcone analytics.

Axiom Space’s partnerships with research organizations and academic institutions aim to deepen understanding of spaceflight’s effects on the human body, with potential applications for Earth-based healthcare. The Ax-4 mission underscores Axiom’s role in redefining access to low-Earth orbit, fostering global collaboration, and advancing microgravity research. As SpaceX’s Dragon enables this historic mission, it reinforces the company’s pivotal role in commercial spaceflight and scientific discovery.

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SpaceX to decommission Dragon spacecraft in response to Pres. Trump war of words with Elon Musk

Elon Musk says SpaceX will decommission Dragon as a result of President Trump’s threat to end his subsidies and government contracts.

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SpaceX will decommission its Dragon spacecraft in response to the intense war of words that President Trump and CEO Elon Musk have entered on various social media platforms today.

President Trump and Musk, who was once considered a right-hand man to Trump, have entered a vicious war of words on Thursday. The issues stem from Musk’s disagreement with the “Big Beautiful Bill,” which will increase the U.S. federal deficit, the Tesla and SpaceX frontman says.

How Tesla could benefit from the ‘Big Beautiful Bill’ that axes EV subsidies

The insults and threats have been brutal, as Trump has said he doesn’t know if he’ll respect Musk again, and Musk has even stated that the President would not have won the election in November if it were not for him.

President Trump then said later in the day that:

“The easiest way to save money in our Budget, Billions and Billions of Dollars, is to terminate Elon’s Government Subsidies and Contracts. I was always surprised that Biden didn’t do it!”

Musk’s response was simple: he will decommission the SpaceX capsule responsible for transporting crew and cargo to the International Space Station (ISS): Dragon.

Dragon has completed 51 missions, 46 of which have been to the ISS. It is capable of carrying up to 7 passengers to and from Earth’s orbit. It is the only spacecraft that is capable of returning vast amounts of cargo to Earth. It is also the first private spacecraft to take humans to the ISS.

The most notable mission Dragon completed is one of its most recent, as SpaceX brought NASA astronauts Butch Wilmore and Suni Williams back to Earth after being stranded at the ISS by a Boeing Starliner capsule.

SpaceX’s reluctance to participate in federally funded projects may put the government in a strange position. It will look to bring Boeing back in to take a majority of these projects, but there might be some reluctance based on the Starliner mishap with Wilmore and Williams.

SpaceX bails out Boeing and employees are reportedly ‘humiliated’

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