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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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Starship Flight 9 nears as SpaceX’s Starbase becomes a Texan City

SpaceX’s launch site is officially incorporated as Starbase, TX. Starship Flight 9 could launch on May 27, 2025. 

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(Credit: Jenny Hautmann/Wikimedia Commons)

SpaceX’s Starbase is officially incorporated as a city in Texas, aligning with preparations for Starship Flight 9. The newly formed city in Cameron County serves as the heart of SpaceX’s Starship program.

Starbase City spans 1.5 square miles, encompassing SpaceX’s launch facility and company-owned land. A near-unanimous vote by residents, who were mostly SpaceX employees, led to its incorporation. SpaceX’s Vice President of Test and Launch, Bobby Peden, was elected mayor of Starbase. The new Texas city also has two SpaceX employees as commissioners. All Starbase officials will serve two-year terms unless extended to four by voters.

As the new city takes shape, SpaceX is preparing for the Starship Flight 9 launch, which is tentatively scheduled for May 27, 2025, at 6:30 PM CDT from Starbase, Texas.

SpaceX secured Federal Aviation Administration (FAA) approval for up to 25 annual Starship and Super Heavy launches from the site. However, the FAA emphasized that “there are other licensing requirements still to be completed,” including policy, safety, and environmental reviews.

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On May 15, the FAA noted SpaceX updated its launch license for Flight 9, but added: “SpaceX may not launch until the FAA either closes the Starship Flight 8 mishap investigation or makes a return to flight determination. The FAA is reviewing the mishap report SpaceX submitted on May 14.”

Proposed Texas legislation could empower Starbase officials to close local highways and restrict Boca Chica Beach access during launches. Cameron County Judge Eddie Trevino, Jr., opposes the Texas legislation, insisting beach access remain under county control. This tension highlights the balance between SpaceX’s ambitions and local interests.

Starbase’s incorporation strengthens SpaceX’s operational base as it gears up for Starship Flight 9, a critical step in its mission to revolutionize space travel. With growing infrastructure and regulatory hurdles in focus, Starbase is poised to become a cornerstone of SpaceX’s vision, blending community development with cutting-edge aerospace innovation.

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United Airlines debuts Starlink Wi-Fi on Detroit flight

United’s first passenger flight with Starlink Wi-Fi just landed in Detroit. Mainline flights to follow by year-end.

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(Credit: United Airlines)

United Airlines debuted Starlink Wi-Fi on its first passenger flight to Detroit, marking a milestone in in-flight connectivity with SpaceX’s satellite internet.

On Thursday, the morning flight from Chicago’s O’Hare International Airport introduced high-speed, gate-to-gate Starlink internet for United Airlines passengers. The Starlink-equipped United Embraer E-175, tail number UA5717, departed at 7:35 a.m. for Detroit Metropolitan Airport.

United announced the rollout on X, stating, “That lightning-fast Wi-Fi we told you about? It’s here. Our first customers just found out what it’s like to break the Wi-Fi barrier and stream, scroll, shop, and game just like at home with Starlink. And it’s FREE for MileagePlus members. Rolling out across our fleet now.”

The service leverages Starlink’s 7,000+ low Earth orbit (LEO) satellites to deliver broadband globally, including in remote areas. United is the only major U.S. airline currently offering Starlink. The airline plans to expand the service across its two-cabin regional fleet and introduce it on mainline flights by year-end.

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Sean Cudahy from The Points Guy tested Starlink’s Wi-Fi pre-launch, praising its ease and reliability. “I ran a speed test, and it clocked the Wi-Fi at 217 Mbps of download speed, and 26.8 Mbps of upload speed,” Cudahy shared, noting its suitability for long flights.

Beyond aviation, SpaceX is pitching Starlink as a GPS alternative, emphasizing its potential for Positioning, Navigation, and Timing (PNT) services. This dual capability underscores Starlink’s versatility.

In a letter to the FCC, SpaceX wrote, “One opportunity stands out as a particularly ripe, low-hanging fruit: facilitating the rapid deployment of next-generation low-Earth orbit (‘LEO’) satellite constellations that can deliver PNT as a service alongside high-speed, low-latency broadband and ubiquitous mobile connectivity.”

As SpaceX expands Starlink’s applications, from aviation to navigation, United’s adoption signals a broader shift toward satellite-driven connectivity on long flights. With plans to equip more aircraft, United and Starlink are redefining in-flight internet, promising seamless digital access at 30,000 feet.

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SpaceX touts Starlink as GPS alternative in FCC PNT push

SpaceX highlighted Starlink’s potential to deliver PNT services alongside its broadband offerings.

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SpaceX is positioning its Starlink constellation as a viable GPS alternative. In a letter to the Federal Communications Commission (FCC), SpaceX stated that it could leverage Starlink satellites for next-generation Positioning, Navigation, and Timing (PNT) solutions.

GPS has been run through a single provider in the United States, the Defense Department. The FCC intends to use Positioning, Navigation, and Timing (PNT) solutions to complement GPS technologies. In its letter, SpaceX highlighted Starlink’s potential to deliver PNT services alongside its broadband offerings in its letter to the FCC.

“As the Commission identifies specific actions to contribute to the whole-of-government PNT system resilience effort, one opportunity stands out as a particularly ripe, low-hanging fruit: facilitating the rapid deployment of next-generation low-Earth orbit (‘LEO’) satellite constellations that can deliver PNT as a service alongside high-speed, low-latency broadband and ubiquitous mobile connectivity,” SpaceX wrote.

SpaceX also emphasized its ongoing work to integrate PNT into its cellular Starlink service, which is expected to be launched with T-Mobile in July. The private space provider also stated that Starlink satellites already operate independently of GPS. This lays the groundwork for resilient PNT delivery across authorized frequencies, SpaceX noted in its letter.

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“SpaceX has also been actively working to integrate PNT solutions into its direct-to-device commercial service offerings. In so doing, SpaceX can advance the Commission’s goal in this proceeding to maintain American leadership in next-generation PNT services both here at home and in over 130 countries it serves around the world.

“SpaceX looks forward to playing an integral role in creating a more robust, resilient, and secure PNT ecosystem for Americans and people around the world,” SpaceX noted.

SpaceX also advocated for a “technology-neutral approach” to GPS alternatives in its letter, while critiquing EchoStar’s unused 2GHz spectrum for mobile satellite services. Meanwhile, Globalstar, Apple’s satellite provider, also pitched its services as a GPS complement, stating that its services “can function as either an alternative or a complement to GPS.”

“Notably, Globalstar’s satellites transmit outside of the L-band, which provides PNT users with added immunity from GPS jamming and spoofing. In addition, Globalstar’s satellite transmissions at 2.4GHz are stronger than GPS signals, bolstering resilience, performance, and reliability,” GlobalStar noted.

SpaceX’s letter to the FCC can be viewed below.

Starlink GPS FCC by maria on Scribd

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