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SpaceX repairing heat shield, reinstalling Raptors on first orbital-class Starship

(NASASpaceflight - bocachicagal)

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4 years ago

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SpaceX has begun reinstalling three of the six Raptor engines that will power the first orbital-class Starship and repairing the heat shield that will hopefully protect it on its first trip to space.

Known as Starship 20 or S20, the 50m (~165 ft) tall steel rocket prototype has been stationed at one of SpaceX’s two suborbital testing pads since August 13th. No testing has been done, though, and a small army of SpaceX technicians and engineers have instead spent the last three or so weeks effectively turning a collection of steel tanks, tubes, and parts into a functional rocket. While it’s unclear why SpaceX chose to do that outfitting work at an unsheltered launch pad, new activity suggests that it may be almost complete.

Exactly one month ago, SpaceX stacked Starship S20 on top of Super Heavy Booster 4 (B4) on August 6th, briefly creating the largest rocket in history and completing a fit test that was admittedly just as much a photo op. Ship 20 was rapidly destacked and returned to SpaceX’s Starbase factory, where all six of its Raptor engines were removed. About a week later, Ship 20 returned to the pad and has remained installed on Suborbital Pad B ever since.

At the time, the implication was that SpaceX had removed Ship 20’s engines to allow the prototype to complete cryogenic proof testing with hydraulic thrust simulators. However, despite having carefully modified Pad B over several weeks for that exact purpose, those modifications were rapidly removed before Ship 20’s second rollout. Precluding a proof test with thrust simulation, the next logical conclusion was that SpaceX would still perform a cryogenic proof test before reinstalling Ship 20’s Raptors and moving on to a static fire campaign.

SpaceX installed Raptors on Ship 20 for the first time on August 4th. One month later, those fit test engines have been replaced with flight hardware. (SpaceX – Elon Musk)

Now, even that appears to have been p1recluded. Instead, as if Ship 20 were the second or third or fourth in a series of prototypes, SpaceX rolled three center Raptors to Pad B on September 5th and began installing the engines on Starship on the 6th. It’s hard to say anything with confidence given how chaotically Starship S20’s to-be-determined qualification testing has changed in the last several weeks but, with plenty of uncertainty, Raptor installation implies that the vehicle will perform its first ambient pressure and cryogenic proof tests with engines installed.

It remains to be seen if Ship 20’s three vacuum-optimized Raptor engines will also be installed over the next few days (seemingly the logical assumption) or if SpaceX will instead complete proof tests and center Raptor static fire testing before finally moving into new territory. SpaceX has never static fired more than three Raptors at once and certainly never tested multiple Raptor Vacuum (RVac) engines in close proximity – let alone all six simultaneously.

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Photos taken on August 18th, 28th, and September 3rd by Philip Bottin and Starship Gazer show the slow, steady process if finishing (and fixing) Starship S20’s heat shield.

Meanwhile, much of the focus of the last few weeks appears to have been on finishing Ship 20 plumbing and avionics wire runs, though it’s hard to say exactly what has been done. What is extremely visible and easy to follow, though, is the process of finishing the first orbital-class Starship heat shield and repairing a few hundred tiles broken during its pathfinder installation. SpaceX has installed 500-1000+ tiles on flown Starship prototypes like SN15 but the company has never come close to the ~15,000 needed to cover the entire windward side of the world’s largest rocket upper stage.

Starship S20’s heat shield, August 26th. (NASASpaceflight – bocachicagal)

SpaceX has undertaken that process for the first time over the last six or so weeks and unsurprisingly seen a number of successes and failures. At some point along the way, a significant fraction of the ceramic, dinner-plate-sized tiles SpaceX technicians installed chipped, broke, shattered, or ran into other fitment issues. Over the last month or so, a great deal of progress has been made fixing those problem tiles and SpaceX has also more or less completed tile installation on the angular ‘aerocovers’ that protect Starship’s flap mechanisms – requiring dozens of custom tiles with complex shapes and curves.

As of September 6th, Starship S20’s heat shield appears to be around 95% complete and the installation of Raptor engines implies that the rocket’s plumbing, avionics, and tankage are also nearly finished. In other words, after many weeks of work, SpaceX’s first orbital-class Starship prototype could be ready to kick off cryoproof and static fire testing just a week or so (and maybe less) from now. Stay tuned for updates!

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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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Tesla and Arevon team up on 172-Megapack solar plus project

One of Tesla’s largest Megapack sites, the Arevon Eland solar project is supported by an impressive 1.2GWh of Megapacks.

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10 hours ago

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March 17, 2025

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Tesla Megapack
Credit: Tesla

Tesla and partner Arevon have completed the second phase of an energy storage site in Southern California, as highlighted in a short video shared this week.

On Monday, Tesla’s Megapack account on X posted a brief video on the Kern County, California “Eland” storage site, which was recently expanded to offer 300MW/1.2GWh of Megapacks supporting 758MW of solar. The so-called “Eland Solar-plus-Storage Project” site now features 172 Megapack units and 1.36 million solar panels, which the companies have previously said is roughly enough to power 200,000 homes annually.

In the video, Tesla also notes that the facility has site-level controls to regulate power output, “providing a firm resource to the grid,” and supporting the Los Angeles climate goal of reaching 100-percent renewable electricity by 2035. You can check out the clip below.

READ MORE ON TESLA MEGAPACKS: Tesla Megapack project in California housed in former steam plant

Arevon announced the official start of operations for Eland 1 in December with 150MW/600 MWh, and the Eland 2 phase has effectively doubled this. The company also appears to be on track for its targeted opening of Eland 2 in Q1 this year, though it’s not clear at the time of writing if Arevon has yet announced a start of operations for the second phase.

Last February, Arevon announced that it secured a $1.1 billion financial commitment for the remaining parts of the Eland 2 Solar-plus-Storage project, together with Eland 1 becoming one of the largest solar-plus-storage installations in the U.S. The projects also include a long-term purchase agreement from the Southern California Public Power Authority, which plans to facilitate contracts for the LA Department of Water and Power and Glendale Water and Power.

Tesla’s grid-scale Megapack batteries can store and deploy generated energy to the electrical grid, especially during periods of peak power usage, high demand, or outages. Coupled with solar or other energy sources in these kinds of solar-plus-storage sites, Tesla’s Megapacks can help support renewable energy for long periods of time, or at least add stability to the grid.

Over the past couple of years, Tesla has been deploying large-scale Megapack projects in markets around the world, as backed by an initial production facility in Lathrop, California. This “Megafactory” aims to eventually produce 10,000 Megapack units, or 40 GWh, per year, and it has been ramping up production since late 2022.

In November, the Lathrop Megafactory officially produced its 10,000th Megapack, and Tesla also started production at a second Megapack plant in Shanghai, China last month, after starting construction on the site last May. The Shanghai Megafactory is also expected to have a volume annual production of 10,000 units per year.

Additionally, Tesla has teased plans for a third Megafactory, though it has yet to disclose where such a facility would be built.

Tesla’s massive Megapack site near Melbourne is almost ready

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Tesla reveals Cybercab battery pack and range efficiency

Tesla aims to make the Cybercab the most efficient EV available, as executives revealed in an interview this week.

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12 hours ago

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March 17, 2025

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Two of the top Tesla executives recently spoke about the Cybercab in an interview with a longtime manufacturing industry expert, sharing details about the electric vehicle’s (EV’s) battery pack size, range, and more.

On Monday, Tesla’s VP of Vehicle Engineering Lars Moravy and Senior Design Executive Franz von Holzhausen told manufacturing industry veteran Sandy Munro that Tesla is targeting a battery pack of under 50kWh for the Cybercab, with “close to” 300 miles of real-world range. This would make the two-seater more efficient than any other EV currently in production, partially due to the two-seater’s highly-aerodynamic design.

Munro says he was expecting a battery pack ranging from 55kWh to 60 kWh, noting how much smaller Tesla is aiming to go. Before revealing the range targets, Moravy also detailed how the Cybercab’s aero wheel covers offer optimal aerodynamics to contribute to the impressive efficiency level.

“As much as Franz hates door handles, I hate the wheel-tire interaction, and this is really the best way for us to get the most aerodynamic wheel-tire we could get,” Moravy explains.

From the wheel covers to the overall design, however, von Holzhausen explains how much thought has gone into making the vehicle so efficient—even down to its shape.

“This car is actually really unique in terms of its teardrop shape,” von Holzhausen said. “It’s actually quite narrow in the rear compared to the front. Obviously, you covered the discs, but the aero efficiency is a huge factor in getting to higher range with a smaller battery pack.”

The fact that the vehicle only has two seats also contributes to some of the design choices Tesla was able to implement, as the executive continues to explain.

“Really, because it’s a two-seater we were able to really narrow the hips on this car, and when you come to the rear, you actually start to see how narrow it is, but it’s not unattractive,” he adds.

Credit: Tesla | X

READ MORE ON TESLA CYBERCAB: Tesla reveals design inspiration behind Cybercab’s gold color

Moravy reiterates that Tesla is already starting to install production equipment for the Cybercab at Gigafactory Texas, which was revealed in a shareholder’s letter in late January. He also echoes plans that Tesla is aiming for prototype builds for the Cybercab by this summer, along with a launch event around early 2026.

In recent weeks, increasing numbers of Cybercabs have also been seen testing at Giga Texas, and longtime drone pilot and factory observer Joe Tegtmeyer said that he saw as many as six driving around the site on Monday.

Last month, Moravy also alluded to plans to make the Cybercab “road-trip-capable,” going long distances with wireless charging along the way to make it completely autonomous for passengers.

Along with talking about the Cybercab’s super-efficient design, the two executives also reiterate discussions about the art deco-inspired design of the robotaxi and the larger Robovan, both of which were unveiled in an event in October. Munro and the executives also go on to sit inside the Robovan while talking a bit about its design.

You can see footage from Teslarati‘s first full ride in the Cybercab below, as captured at the “We, Robot” event in Southern California. Or, check out the full Cybercab and Robovan episode from Munro, Moravy, and von Holzhausen below that, clocking in at just under 25 minutes.

Tesla says its Cybercab wireless charging efficiency is ‘well above 90%’

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SpaceX rescue mission for stranded ISS astronauts nears end — Here’s when they’ll return home

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13 hours ago

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March 17, 2025

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Credit: SpaceX

SpaceX is ready to bring home Butch Wilmore and Suni Williams, the two astronauts that have been stranded on the International Space Station (ISS) for nine months.

Last week, SpaceX launched its Crew-10 mission, which would dock onto the ISS late Saturday night and be the two astronauts’ ride home. Now, the end is in sight, and it appears both NASA and SpaceX are planning to have the two home this week, perhaps earlier than expected.

SpaceX readies to rescue astronauts from International Space Station

The agency and the company have announced that Dragon will autonomously undock from the ISS on Tuesday at 1:05 a.m. ET and should re-enter Earth’s atmosphere and splashdown off the Florida coast about 17 hours later.

SpaceX said:

“SpaceX and NASA are targeting Tuesday, March 18 at 1:05 a.m. ET for Dragon to autonomously undock from the International Space Station. After performing a series of departure burns to move away from the space station, Dragon will conduct multiple orbit-lowering maneuvers, jettison the trunk, and re-enter Earth’s atmosphere for splashdown off the coast of Florida approximately 17 hours later the same day.”

Crew-9 astronaut Nick Hague will be alongside Williams and Wilmore on the flight home, along with Roscosmos cosmonaut Aleksandr Gorbunov. Hague and Gorbunov have been in space since Saturday, September 28.

SpaceX was tasked with bringing Wilmore and Williams home after the Boeing Starliner that sent them there was determined not to be suitable for their return.

A report from the New York Post in late August said that Boeing employees routinely made fun of SpaceX workers, only for the company to bail them out:

SpaceX bails out Boeing and employees are reportedly ‘humiliated’

Crew-10 will bring the astronauts home, ending an extensive and unscheduled stay in space.

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