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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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4 years ago

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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.

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.

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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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Elon Musk reveals SpaceX’s target for Starship’s 10th launch

Elon Musk has revealed SpaceX’s target timeline for the next Starship launch, which will be the tenth in program history.

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7 hours ago

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July 16, 2025

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Credit: SpaceX

Elon Musk has revealed SpaceX’s target timeline for the next Starship launch, which will be the tenth in program history.

Musk says SpaceX is aiming for a timeline of roughly three weeks from now, which would come about ten weeks after the previous launch.

Coincidentally, it would bring the two launches 69 days apart, and if you know anything about Elon Musk, that would be an ideal timeline between two launches.

SpaceX is coming off a test flight in which it lost both the Super Heavy Booster and the Upper Stage in the previous launch. The Super Heavy Booster was lost six minutes and sixteen seconds into the flight, while SpaceX lost communication with the Ship at 46 minutes and 48 seconds.

Musk is aiming for the tenth test flight to take place in early August, he revealed on X:

This will be SpaceX’s fourth test flight of the Starship program in 2025, with each of the previous three flights bringing varying results.

IFT-7 in January brought SpaceX its second successful catch of the Super Heavy Booster in the chopstick arms of the launch tower. The ship was lost after exploding during its ascent over the Turks and Caicos Islands.

IFT-8 was on March 6, and SpaceX caught the booster once again, but the Upper Stage was once again lost.

The most recent flight, IFT-9, took place on May 27 and featured the first reused Super Heavy Booster. However, both the Booster and Upper Stage were lost.

The Federal Aviation Administration (FAA) hit SpaceX with a mishap investigation for Flight 9 on May 30.

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Elon Musk confirms Tesla is already rolling out a new feature for in-car Grok

Tesla is already making in-car Grok more robust with a simple but effective feature that CEO Elon Musk says is “coming.”

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14 hours ago

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July 16, 2025

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Credit: Tesla

Tesla CEO Elon Musk has confirmed that the company will roll out a new feature for in-car Grok as it is rolling out to vehicles for the first time.

Grok was just recently added as a feature to Tesla vehicles within the past week, but owners are already requesting some small changes to make it more convenient to use.

Tesla debuts hands-free Grok AI with update 2025.26: What you need to know

The first is already on the way, Musk confirmed, as WholeMarsBlog requested a simple, but useful feature for Grok as it is used within Tesla vehicles.

Whole Mars requested that “Hey Grok” be used as a wake word, automatically activating the AI assistant without having to touch any buttons. Musk confirmed it is already in development and on the way to vehicles:

This feature is incredibly similar to that of “Hey Siri” with iPhones and other iOS devices. The phone will recognize your voice and hear that prompt, automatically activating Siri. Apple’s assistant will then perform whatever task it is asked to perform. It’s a simple but effective performance feature.

Grok is already getting its first reviews from owners as it rolls out to owners for the first time. It is a long time coming, too. Tesla has been hinting that Grok would be enabled in the vehicles for a while now, and it just started its initial rollout last week.

Grok is available in vehicles with the AMD chip and requires Premium Connectivity or a WiFi connection to use.

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Tesla reveals key detail of Supercharger Diner, but it’s bigger than you think

Tesla has finally released one key detail about the Supercharger Diner, and it is bigger than what it appears at face-value.

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16 hours ago

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July 16, 2025

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tesla-diner-supercharger
Credit: Tesla

Tesla has revealed a key detail of its Supercharger Diner as its launch date appears to be nearing, based on what we are seeing at the site currently.

The Supercharger Diner is located on Santa Monica Boulevard in Los Angeles and was first proposed as an idea by CEO Elon Musk back in 2018. Musk envisioned a drive-in movie-style 1950s-inspired diner that would feature elements such as servers on roller skates, large movie screens, and a menu inspired by classic treats from several decades ago.

A project that first broke ground in 2023, the Supercharger Diner has been in development for over two years, as Tesla performed demolition work at the site back in February of that year.

It has slowly moved forward, and drone footage shot this week seems to show things are nearly up and running. Musk even mentioned that he had eaten at the Diner Supercharger this week.

There are still details that Tesla has yet to announce and confirm. The most important thing is regarding the menu that will be served at the diner.

Tesla has not hinted at what it will be making for patrons at the restaurant, but Musk commended the food and said the diner would be one of the coolest spots in LA.

However, we now have details on another important thing about the restaurant: the hours.

Images taken by Aaron Cash of ABetterTheater.com show the diner will be open 24/7, as it appears on the front doors of the diner:

At first thought, it seems this will operate like any other diner, as many are open for 24 hours a day. Diners typically serve large menus with numerous options, catering to the tastes and moods of anyone who walks in.

People of all walks of life eat at diners, as the food is typically affordable, tasty, and available at any hour to serve those who are night owls or those who work non-typical schedules.

However, Tesla is a bit different, and it seems that this new venture into food service could eventually transition from human servers and cooks to robots, most notably the company’s in-house project of Optimus.

It is something straight out of a Star Wars movie. I can think of Obi-Wan Kenobi visiting Dex in his diner in Attack of the Clones to figure out where a poison dart was sourced from:

Eventually, Optimus will likely be working as an employee in the Tesla Diner, and 24/7 operation will be performed by the humanoid robot that aims to eliminate trivial tasks from humans.

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