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SpaceX’s first orbital-class Starship stretches ‘wings’ ahead of Raptor installation

SpaceX unleashed Starship S20's flaps for the first time on Sunday. (NASASpaceflight)

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SpaceX’s first orbital-class Starship prototype was spotted stretching its ‘wings’ on Sunday after completing a successful cryogenic proof test late last week.

While minor relative to almost any other testing milestone, the small step still serves as a reminder that the end goal of Ship 20’s test campaign is a launch on Super Heavy to orbital altitudes and velocities. If that launch goes more or less according to plan, Starship will then attempt to survive an orbital-class reentry for the first time, subjecting it to extreme heat and putting its many thousands of heat shield tiles through their most daunting challenge yet. Dozens of things could (and probably will) go wrong, while almost every system aboard must work perfectly to ensure that Starship makes it through reentry in one piece.

And even if all of that occurs as planned with no major issues, those same systems will still need to hold on for several more minutes to perform a freefall, engine reignition, flip, and landing maneuver that only two other Starship prototypes have completed. As it so happens, one of those crucial systems is Starship’s flaps.

Outfitted with actuators powered by Tesla Model 3/Y motors and a pair of Model S batteries, Starship’s four large ‘flaps’ are only capable of simple flapping motions. While they may look the part, Starship flaps aren’t wings and are specifically designed not to produce lift. Instead, in support of Starship’s unusual descent profile, they act more like the hands and legs of a skydiver (particularly one in a wingsuit), allowing ships to control their pitch, attitude, and roll while freefalling belly-down to the ground. In theory, that allows Starship to gain practically all of the benefit of a structural wing like that on the Space Shuttle but for a far lower mass penalty.

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Instead of elegantly slowing down with wings, Starship uses its flaps to create as much drag as possible during descent, slowing down to a terminal velocity around 100 m/s (~225 mph) or less. Using a freefall trajectory and flaps incapable of generating lift does likely come at the cost of “crossrange performance,” referring to how far Starship can travel horizontally in Earth’s atmosphere after reentry. However, significant crossrange performance is almost entirely irrelevant outside of Cold War paranoia like the kind that NASA let influence the Shuttle’s design to an ultimately catastrophic degree. Landing vertically also precludes the need for exceptionally long, expensive runways like those the Shuttle needed.

A cutaway view of one of Shuttle’s wing elevon hinges and associated seals. (NASA)
Space Shuttle Endeavor shows off its heat shield (and flaps) during an on-orbit inspection in 2007. (NASA)

Aside from allowing it to navigate to a small vertical landing pad (or massive ‘Mechazilla’ catch tower), Starship’s flaps are also important for controlling vehicle orientation and heading during reentry itself. To fill that role, those flaps will have to be able to actuate across their full range of motion during reentry, as Starship’s hypersonic assault against the thin upper atmosphere creates a flood of superheated plasma that wants nothing more to find the gaps in its heat shield. Shuttle engineers had to deal with the same issue, ultimately designing complex seals that would allow the vehicle’s wing and body flaps to actuate during reentry without allowing superheated plasma to leak inside and damage their fragile mechanisms or structure.

Although Starship does have the benefit of relying on steel – not aluminum – for almost all of its structures, it still has to grapple with the same challenges of shielding sensitive electronics, actuators, motors, and more from the reentry onslaught that its heat shield and steel structure are designed to survive.

(NASASpaceflight – bocachicagal)
Starship’s flaps practically sit flush with their aerocover heat shielding when installed. (NASASpaceflight – bocachicagal)

Half-covered in heat shield tiles, it’s not clear how SpaceX plans to seal off the more sensitive, exposed components of each flap’s actuation mechanism – including motors, cabling, and the hinge itself. Based on what’s visible, Starship’s flaps and the cradle-like ‘aerosurfaces’ they slot into do have very tight tolerances and may rely on some felt-like ceramic wool or TPS blanket to seal the tiny remaining gaps. With small enough gaps, a hypersonic airstream can behave as if there are no gaps at all, suggesting that that might be SpaceX’s preferred approach to sealing Starship flaps.

Up next on Starship S20’s path to launch is the reinstallation of 3-6 Raptor engines (for the third time) ahead of a crucial static fire test campaign that could begin as early as Thursday, October 7th. Likely beginning with 1-3 Raptors, SpaceX will perform an unknown number of static fire tests, ultimately culminating in the first ignition of 4, 5, and 6 engines on any Starship prototype. If all goes well, that testing will also mark the first time Raptor Vacuum has been ignited on a Starship prototype and the first time SpaceX has ignited multiple Raptor variants (sea level and vacuum, in this case) on the same vehicle. Stay tuned for updates on engine installation.

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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 Board has set a Mars bonus for Elon Musk

SpaceX has given Elon Musk the goal to put one million people on Mars.

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Rendering of a colonized Mars by way of SpaceX

SpaceX’s board approved a compensation plan for Elon Musk that ties his pay directly to colonizing Mars and building data centers in outer space. The details surfaced this week after Reuters reviewed SpaceX’s confidential registration statement filed with the Securities and Exchange Commission, making it one of the first concrete looks inside the company’s financials ahead of a public offering.

The pay package will reportedly award Musk 200 million super-voting restricted shares if the company hits a market valuation milestone, with the most ambitious targets going further. To unlock the full award, SpaceX would need to reach a $7.5 trillion valuation and help establish a permanent human settlement on Mars with at least one million residents. Additional incentives are tied to developing space-based computing infrastructure capable of delivering at least 100 terawatts of processing power.

SpaceX wins its first MARS contract but it comes with a catch

Long before SpaceX filed anything with the SEC, Elon Musk had already spent years framing Mars colonization as an insurance policy against human extinction. The philosophy traces back to at least 2001, when Musk first began researching Mars missions independently, before SpaceX even existed. By 2002 he had founded the company with Mars as the stated long-term goal.

In a 2017 presentation at the International Astronautical Congress, Musk outlined the specific vision that still underpins SpaceX’s architecture today. He described a self-sustaining city on Mars requiring roughly one million people to become viable, the same number now written into his compensation package.

SpaceX’s Starship, still in active development, was designed from the ground up to support the eventual colonization of Mars. Musk has stated publicly that getting the cost per ton to Mars below $100,000 is necessary to make mass migration economically feasible. Everything from Starship’s payload capacity to its full reusability targets flows from that single constraint. One can say that Musk’s latest compensation package has put a formal valuation on Mars for the first time.

SpaceX is targeting an IPO around June 28, Musk’s birthday, at a valuation of approximately $1.75 trillion. Between the Mars rover contract, the Golden Dome software group, Space Force satellite launches, and now a pay structure built around interplanetary colonization, SpaceX has become the single most consequential contractor in American space and defense. The IPO will put a public price tag on all of it for the first time.

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Tesla’s biggest rivals fights charging wait times with a modern approach

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Tesla V4 Supercharger installation ramping in Europe

Earlier this week, we wrote a story on how Tesla is launching a new Supercharging Queue system to mitigate problems between drivers when there is a wait to charge.

Rather than potentially having people end up in a physical conflict, Tesla’s approach is to determine who is next to charge based on geographic data.

Tesla launches solution to end Supercharger fights once and for all

But some companies, notably Tesla’s biggest rival in China, BYD, are taking a different approach, focusing on charging speeds rather than how they will manage delays.

BYD’s approach, especially with its tests of ultra-fast “Flash Charging” technology, is to eliminate the length of a charging session. At the heart of this strategy is BYD’s second-generation Blade Battery paired with 1,500-kW Flash Chargers.

Unveiled earlier this year, the system charges compatible vehicles from 10 percent to 70 percent state of charge in just five minutes and from 10 percent to 97 percent in nine minutes.

Real-world demonstrations on models like the Yangwang U7 and Denza Z9 GT have shown the tech delivering roughly 250 miles (400 kilometers) of range in just five minutes. This would essentially match or beat the time it takes to fill a gas tank.

Sometimes, gas pumps get congested, and there are lines. You rarely see conflicts at pumps because filling up a tank rarely takes more than five minutes.

Tesla’s fastest Supercharger build currently is the v4, which can deliver up to 325 kW for Cybertruck and 250 kW for other models, but there are “true” sites that are capable of up to 500 kW. This enables speeds of up to 1,000 miles per hour, or 1,400 miles for 350 kW-capable vehicles.

The breakthrough stems from BYD’s vertically integrated ecosystem: a new 1,000-volt architecture, 10C charging rates, and proprietary silicon-carbide chips that minimize internal resistance while protecting battery health.

The company plans to install 20,000 Flash Charging stations across China by the end of 2026, with thousands already operational and global expansion eyed for Europe and beyond later this year.

Early rollout targets popular models, including upgrades to high-volume sellers like the Seal and Sealion series, bringing five-minute charging to mainstream prices around 100,000 yuan (about $14,000).

This approach contrasts sharply with Tesla’s software solution. Tesla’s Virtual Queue uses geofencing and the app to assign turns at crowded sites, addressing driver disputes and idle time. It’s a clever fix for today’s network realities.

Yet, BYD’s philosophy is simpler: make charging so fast that waits barely exist. A five-minute stop becomes as convenient as a gas-station visit, reducing station dwell time, easing grid strain, and lowering range anxiety for long trips.

For consumers, the difference is potentially tangible. They’ll spend more time driving and less time parked. It is just another way Tesla and BYD are pushing one another to improve the overall experience of EV ownership.

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Tesla wins big as NHTSA drops three-year, 120k unit probe against Model Y

In all, 120,089 Model Ys were impacted, but in two cases, drivers reported the complete detachment of the steering wheel from the steering column while the vehicle was in motion. NHTSA’s initial review revealed that the vehicles had been delivered without the critical retaining bolt that secures the steering wheel to the splined steering column.

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Credit: Tesla Asia | X

A probe into over 120,000 2023 Tesla Model Y units has been closed by the National Highway Traffic Safety Administration (NHTSA). The probe ends without the agency requiring any action from Tesla.

The probe, designated PE23-003, opened in March 2023 and stemmed from just two consumer complaints involving low-mileage Model Y SUVs.

In all, 120,089 Model Ys were impacted, but in two cases, drivers reported the complete detachment of the steering wheel from the steering column while the vehicle was in motion. NHTSA’s initial review revealed that the vehicles had been delivered without the critical retaining bolt that secures the steering wheel to the splined steering column.

Factory records showed each car had undergone an “end-of-line” repair at Tesla’s facility, during which the steering wheel was removed and reinstalled. The bolt was apparently omitted after the repair, leaving only a friction fit between the wheel and column to hold it in place temporarily.

According to NHTSA documents, this friction fit maintained the connection during initial low-mileage driving until forces during normal operation caused the wheel to detach. Both vehicles that were impacted were repaired under warranty with no injuries reported, and no additional incidents surfaced during the agency’s three-year review.

Tesla Model Y steering wheel detachments prompt NHTSA probe

After analyzing manufacturing processes, complaint data, and field reports, NHTSA concluded the issue was isolated to those two post-repair vehicles rather than indicative of a systemic defect in Tesla’s production or quality control.

The closure means the agency has determined no recall or further enforcement is warranted for this specific missing-bolt condition.

This outcome marks the second NHTSA investigation into Tesla closed without action this month, as a recent probe into the company’s “Actually Smart Summon” feature was also resolved in April.

Tesla Full Self-Driving feature probe closed by NHTSA

The two resolutions provide some relief for Tesla amid the continuous and somewhat unfair regulatory scrutiny of its vehicles, including open inquiries into driver assistance systems.

Importantly, the closed probe does not involve or affect Tesla’s separate May 2023 voluntary recall of certain 2022-2023 Model Y vehicles. That recall addressed a different issue—steering-wheel fasteners that were installed but not torqued to specification—prompted by a service technician’s observation of a loose wheel during unrelated repairs.

Tesla identified a small number of related warranty claims and proactively addressed the matter without NHTSA mandate.

The Model Y remains one of the world’s best-selling vehicles, and Tesla continues to refine its lineup, including the recent “Juniper” refresh. While federal oversight of the electric vehicle pioneer remains intense, this decision underscores that isolated manufacturing anomalies do not always translate into broader safety defects requiring recalls.

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