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SpaceX’s orbital Starship prototype sheds tiles, comes to life during first tests

Framed by Super Heavy boosters B3 and B4, Starship S20 comes to life for the first time. (NASASpaceflight - bocachicagal)

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After weeks of mostly invisible – albeit slow and steady – work at Starbase’s suborbital launch and test facilities, SpaceX has finally kicked off the first orbital Starship prototype’s first test campaign.

Almost two months ago, Starship 20 (S20) departed the factory it was built in for the first time and was rolled a few miles down a South Texas highway to Starbase’s nascent orbital launch site. There, SpaceX briefly installed Ship 20 on top of Super Heavy Booster 4 (B4) – an important first and one done with the same ship and booster pair CEO Elon Musk says could eventually support the rocket’s inaugural orbital launch attempt. Mere hours after that August 6th photo opportunity and fit test, Ship 20 was rolled back to the Starbase build site for another week of work before again returning to the launch site.

This time around, Starship S20 headed for one of two suborbital launch and test stands and ultimately spent the better part of the next six weeks sitting in place as workers swarmed around the 50m (~165 ft) tall spacecraft and upper stage to prepare it for the next steps. In theory, those steps were simple enough, beginning with the completion of two basic qualification tests – the same tests that a half-dozen prototypes preceding Ship 20 completed without issue.

(NASASpaceflight – bocachicagal)

Effectively SpaceX’s first Starship or Super Heavy test of any kind in more than two months, it thankfully didn’t take long for things to get interesting. Before the pad had even been cleared of the last few remaining workers, Starship S20 violently shed a good dozen or so fragile heat shield tiles. CEO Elon Musk quickly confirmed speculation that Starship S20 had effectively jetted the tiles off its nose during a brief test of high-pressure cold gas maneuvering thrusters, coincidentally around the same time as SpaceX began to pressurize the rocket for its first tests.

Note the large cutout (header tank vent) and five smaller cutouts (cold gas thrusters) just below it. Musk says one of those thrusters blew away some of the adjacent heat shield tiles. (NASASpaceflight – bocachicagal)

Going into what was believed to be Starship S20’s first ambient-temperature pressure test and cryogenic proof test, the loss of some heat shield tiles was almost universally expected. In a structure as large as Starship, even just the thermal contraction of steel at supercool temperatures (and expansion as it warms back up) could change the rocket’s diameter an inch or so, potentially causing tiles to scrape or press against each other. About the size of a dinner plate and the thickness of an average paperback book, Starship’s ceramic heat shield tiles have proven to be very fragile, with dozens routinely chipping, cracking, and shattering during and after installation on Ship 20.

One unique (and no less unproven) aspect of Starship is SpaceX’s decision to mount its heat shield directly to the thin steel propellant tanks and skin that make up the rocket’s entire airframe. SpaceX’s first stab at the problem involves studs/pins welded – by robot – directly to the exterior of Starship’s tanks and skin. By embedding small metal plates inside each cast tile, they can be easily installed by aligning the tile and pressing it against each set of three barb-like pins, which then irreversibly lock in place. Over most of Starship’s hull, SpaceX then tacks on blankets of off-the-shelf ceramic wool insulation before tiles are installed on top of that steel and blanket sandwich. Compared to the Space Shuttle and Russia’s Buran, the only other orbital spacecraft to fly with non-ablative heat shields, Starship’s thermal protection system (TPS) is incredibly simple. Of course, the challenges imposed on heat shields by mechanical stresses during launch/landing, orbital reentry, and a need for rapid reusability are anything but simple.

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As such, to see tiles blown off Starship S20 by cold gas maneuvering thrusters that were simply placed too close to adjacent TPS was an unexpected route to an expected outcome. During Monday’s nine-hour test window, SpaceX appeared to partially or fully pressurize Starship S20 at ambient temperatures before aborting a cryogenic proof test either before or just after it began. While an ambient-temperature proof was the easier of the two tests on the docket, it’s still encouraging to see no obvious tile loss caused by the actual mechanical stresses involved in the test.

Most importantly, compared to losing dozens of tiles to regular mechanical or thermal stresses, fixing an issue with thruster impingement is much easier and should only require a few design tweaks to one specific Starship component. The real nail-biting moments will come during Starship S20’s seemingly imminent cryogenic proof and static fire debuts, major TPS issues during either of which could necessitate vehicle-wide design changes and cause delays.

With any luck, whatever forced SpaceX to abort Starship S20’s first cryogenic proof test can be easily rectified, opening the door for additional attempts. Two more test windows are scheduled later this week from 5pm to 11pm CDT on Tuesday and Wednesday. Rewatch today’s brief testing below.

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 stuns with another FSD approval in Europe, its second in two days

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Tesla has stunned by gaining yet another approval for its Full Self-Driving suite in Europe, its second in two days and its fifth overall.

Belgium will be the latest country to allow Tesla owners to utilize FSD on public roads in Europe, joining a quickly growing list that started with the Netherlands, Lithuania, and Estonia.

On Tuesday, Denmark announced its approval of the FSD suite, which has now been followed by Belgium just one day later.

The country’s Minister of Mobility, Annick De Ridder, announced the approval on her X account, stating that she had just signed the approval of Tesla FSD. It now goes to the country’s homologation department for the last step of the approval process.

The Belgian approval is one of mighty importance because it truly shows how quickly countries in Europe could greenlight the FSD suite consecutively. Approvals are already coming in relatively quickly, which is a great sign.

Perhaps the next big development that could come from FSD approvals in Europe is an approval from a country like England, Italy, France, Spain, or Germany. It would be something to see how FSD would perform in a major European metro, such as London, Barcelona, Madrid, Paris, Rome, or Berlin.

Full Self-Driving does an excellent job of roaming around major U.S. cities like New York and Los Angeles, but other high-profile international cities of significance would truly mark a line in the sand for Tesla, which can simply enable any vehicle in its customer-owned fleet to run FSD with the correct approvals.

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Elon Musk

SpaceX’s Elon Musk relieves worries about orbital data centers

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Rendering of Elon Musk overlooking a Starship fleet (Credit: Grok)
Rendering of Elon Musk overlooking a Starship fleet (Credit: Grok)

SpaceX CEO Elon Musk recently confronted worries about orbital data centers and launching satellites in mass quantities in space, as some voiced concerns about crowding.

Musk’s SpaceX plans to combat the issue of needing data centers by launching them into space instead of taking up valuable real estate on Earth. It has been a major point of SpaceX’s future, including its looming IPO, which could be the largest ever.

In a recent interview filmed at SpaceX’s Starlink terminal factory in Bastrop, Texas, Elon Musk directly addressed concerns that deploying large numbers of AI satellites for orbital data centers could crowd Earth’s orbit. His message was straightforward and reassuring: space is vast beyond human intuition.

“Space is really big,” Musk said. “It’s not like space is gonna get crowded. Space is enormous. If you actually look at it relative to the Earth, the satellites are so tiny you can’t even see them.” He emphasized that even zooming in makes a satellite appear large, but from a planetary perspective, they are minuscule specks.

Musk pointed to SpaceX’s real-world experience operating roughly 10,000 Starlink satellites as evidence that large constellations can be managed safely. “We’ve got a pretty good idea of how to operate just really large constellations and do it safely,” he noted. SpaceX remains the only operator with meaningful experience at this scale, giving the company unique insight into tight orbital packing without compromising safety

The discussion highlighted SpaceX’s plans for “AI1” satellites—essentially orbiting racks of AI compute powered by massive solar arrays and cooled via radiative panels in space’s vacuum.

These satellites leverage proven Starlink V3 technology, making them simpler to design than communications satellites. A first-generation unit targets around 150 kW peak power, with a 70-meter wingspan for solar panels and radiators. Laser links will connect them to each other and the Starlink network, delivering low-latency access (on the order of a few milliseconds from low-Earth orbit).

FCC accepts SpaceX filing for 1 million orbital data center plan

Musk framed orbital data centers as a practical solution to Earth’s constraints on AI growth. Ground-based facilities face power shortages, water demands for cooling, and grid limitations. In space, constant sunlight (no day-night cycle), vacuum radiative cooling, and abundant solar energy offer clear advantages.

Production will ramp up at an expanded “Gigasat” factory in Bastrop, with solar manufacturing already underway and full AI satellite output expected at reasonable volume by the end of 2027. Starship’s rapid, high-volume launch capability, aiming for multiple flights per hour, will make massive deployment feasible.

Critics sometimes raise risks like space debris or Kessler syndrome, but Musk’s response underscores scale: even a million satellites would represent an imperceptible fraction of available orbital volume when viewed against Earth’s size. SpaceX’s automated collision avoidance and deorbiting designs for Starlink further mitigate concerns.

This vision ties into broader ambitions. Musk sees orbital AI compute as a step toward harnessing more of the Sun’s energy, advancing humanity on the Kardashev scale from a Type 0 civilization toward Type 1 and eventually Type 2. By moving power-hungry data centers off-planet, SpaceX aims to unlock orders-of-magnitude more compute while preserving Earth’s resources.

Musk’s comments should ease public anxiety. With proven operational expertise, incremental engineering, and the immensity of space itself, orbital data centers represent not overcrowding, but smart expansion into the final frontier.

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Investor's Corner

Tesla Full Self-Driving hits Level 4? One analyst says yes

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Credit: Tesla

Tesla Full Self-Driving (Supervised) is currently listed as a Level 2 suite in terms of its passenger cars. As its Robotaxi platform continues to move quickly, it has been recognized as a Level 4 ride-sharing program by the State of Texas, as Tesla recently self-certified itself.

However, a Wall Street analyst is arguing that Tesla (NASDAQ: TSLA) has effectively achieved Level 4 autonomy in most conditions in all of its vehicles, drawing on personal experience and data released by the company.

Alex Potter of Piper Sandler said in a note to investors on Wednesday that “Tesla has solved the self-driving puzzle,” pointing to decisions to offer insurance discounts for FSD-enabled policies as a signal of confidence, which is backed up by stellar safety records compared to human driving.

Investing.com initially reported on Potter’s new note.

Additionally, Potter looks at the recent start of Cybercab production at Giga Texas as a potential indication that Tesla is ready to offer some level of unsupervised driving at least in the near future. The Cybercab has no steering wheel or pedals, completely eliminating the ability for human input.

He also sees Tesla’s allocation of “several hundred million USD (if not $1B+)” as confidence internally, seeing as it would be tough to set aside that amount of capital toward a project that the company does not see as relatively near-term.

Forward thinking, especially as Cybercab has no human controls, it would make sense that Tesla is at least close to self-driving. How close is another question.

Tesla has routinely teased that unsupervised FSD is close, but there are still a lot of things it feels as if the company has to roll out some more capability, including unsupervised parking features, known as “Banish,” better operation with regional self-driving performance, and other improvements.

That is not to say that Tesla FSD is super impressive already. It has already completed coast-to-coast drives across the United States and Canada, it routinely takes the stress out of driving for most people, and it has proven through Tesla Safety Reports that it is safer and involved in accidents less frequently than humans.

Even Potter believes it is capable, as he used it to go from Missoula, Montana, to Minneapolis, Minnesota, back in April.

“There’s no substitute for personal experience,” he wrote.

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