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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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Ukraine completes first Starlink direct-to-cell test in Eastern Europe

The trial was announced by the Ministry of Digital Transformation and Kyivstar’s parent company Veon, in a press release.

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Credit: SpaceX

Ukraine’s largest mobile operator, Kyivstar, has completed its first test of Starlink’s Direct to Cell satellite technology, enabling text messages to be sent directly from 4G smartphones without extra hardware. 

The trial was announced by the Ministry of Digital Transformation and Kyivstar’s parent company Veon in a press release.

First Eastern Europe field test

The Zhytomyr region hosted the pilot, where Deputy Prime Minister Mykhailo Fedorov and Kyivstar CEO Oleksandr Komarov exchanged texts and even made a brief video call via Starlink’s satellite link in northern Ukraine’s Zhytomyr region. 

Veon stated that the test marked Eastern Europe’s first field trial of the technology, which will allow Kyivstar’s 23 million subscribers to stay connected in areas without cellular coverage. The service will debut in fall 2025 with free text messaging during its testing phase.

“Our partnership with Starlink integrates terrestrial networks with satellite platforms, ensuring that nothing stands between our customers and connectivity – not power outages, deserts, mountains, floods, earthquakes, or even landmines,” Veon CEO Kaan Terzioglu stated.

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Starlink in Ukraine

Kyivstar signed its Direct to Cell agreement with Starlink in December 2024, about a year after a major cyberattack disrupted service and caused nearly $100 million in damages, as noted in a report from the Kyiv Independent. Starlink technology has been a pivotal part of Ukraine’s defense against Russia in the ongoing conflict.

“Despite all the challenges of wartime, we continue to develop innovative solutions, because reliable communication under any circumstances and in any location is one of our key priorities. Therefore, this Kyivstar project is an example of effective partnership between the state, business, and technology companies, which opens the way to the future of communication without borders,” Mykhailo Fedorov, First Deputy Prime Minister of Ukraine, said.

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SpaceX is rolling out a new feature to Starlink that could be a lifesaver

Starlink now has a new Standby Mode that will enable low-speed internet access in the event of an outage.

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(Credit: Starlink | X)

SpaceX is rolling out a new feature to Starlink that could be a lifesaver in some instances, but more of a luxury for others.

Starlink is the satellite internet service that Elon Musk’s company SpaceX launched several years ago. It has been adopted by many people at their homes, many airlines on their planes, and many maritime companies on their ships.

SpaceX produces its 10 millionth Starlink kit

It has been a great way for customers to relieve themselves of the contracts and hidden fees of traditional internet service providers.

Now, Starlink is rolling out a new service feature on its units called “Standby Mode,” which is part of Pause Mode. The company notified customers of the change in an email:

“We’re reaching out to you to let you know the Pause feature on your plan has been updated. Pause now includes Standby Mode, which comes with unlimited low-speed data for $5.00 per month, perfect for backup connectivity and emergency use. These updates will take effect in 30 days. All of your other plan features remain the same. You are able to cancel your service at any time for no charge.”

SpaceX did not define how fast these “low speeds” will be. However, there are people who have tested the Standby Mode, and they reported speeds of about 500 kilobytes per second.

The mode is ideal for people who might deal with internet or power outages, but still need to have some sort of internet access.

It could also be used as a backup for people who want to stay with their ISP, but would like to have some sort of alternative in case of an outage for any reason.

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SpaceX starts offering Starship services for Mars, and it already has its first customer

SpaceX has started offering Starship services to Mars, and it has its first customer already.

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Credit: SpaceX/X

SpaceX is yet to master its Starship spacecraft, but the company is already planning several steps ahead. As per recent updates from company leadership, SpaceX has started offering Starship services to Mars, and it has its first customer already.

Starship Updates

SpaceX President and COO Gwynne Shotwell recently posted an update about SpaceX’s Starship program on social media platform X. As per the executive, the private space company is now “offering Startup services to the red planet.” Shotwell also noted that SpaceX is working with the Italian Space Agency on an agreement.

Italian Space Agency President Teodoro Valente shared his excitement for the project in a post on X. As per Valente, the payloads in the mission would be gathering scientific data from Mars. 

“Italy is going to Mars! @ASI_Spazio and @SpaceX have signed a first-of-its-kind agreement to carry Italian experiments on the first Starship flights to Mars with customers. The payloads will gather scientific data during the missions. Italy continues to lead in space exploration!” Valente wrote in his post.

Next Starship Flight

SpaceX is currently making preparations for the launch of Starship Flight 10, which is expected to be held sometime this August, as per previous comments from CEO Elon Musk. At the end of July, SpaceX fired up its Starship Upper Stage on its South Texas launch site. This ship is the second that SpaceX has earmarked for Flight 10, as noted in a Space.com report, since the first exploded on a test stand on June 18 just before a planned static fire test.

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A fully-stacked Starship first took to the skies in April 2023. Unfortunately, the last three missions this year, which were launched in January, March, and May, all ended with the upper stage experiencing a Rapid Unscheduled Disassembly (RUD) before its planned splashdown in the Indian Ocean. 

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