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SpaceX sends “radically redesigned” Starship engine to Texas for hot-fire tests

As of September 2017, subscale Raptor engines had been cumulatively fired for more than 1200 seconds in just 12 months of testing. (SpaceX)

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7 years ago

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SpaceX has shipped one of the first of a group of Starship engines known as Raptor, described last month by CEO Elon Musk as “radically redesigned”. A culmination of more than 24 months of prototype testing, the first flight-worthy Raptor could be ignited for the first time as early as February.

According to Musk, three of these redesigned Raptors will power the first full-scale BFR prototype, a Starship (upper stage) test article meant to conduct relatively low-altitude, low-velocity hop tests over the southern tip of Texas. Those tests could also begin next month, although a debut sometime in March or April is increasingly likely.

Effectively designed on a blank slate, Raptor began full-scale component-level tests in 2014 at NASA’s Mississippi-based Stennis Space Center, evolving from main injector development to oxygen preburner hot-fires in 2015. Soon after Raptor’s prototype preburner design was validated at Stennis, SpaceX moved testing to its privately-owned and operated facilities in McGregor, Texas, where Raptor static fire testing has remained since.

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Just days before CEO Elon Musk was scheduled to reveal SpaceX’s next-generation rocket (BFR, formerly known as the Interplanetary Transport System or ITS) in September 2016, he announced in a tweet that propulsion engineers and technicians had successful hot-fired an integrated Raptor prototype – albeit subscale – for the first time ever. Just 12 months later, Musk once again took to the stage to announce an update to BFR’s design, while also revealing that prototype Raptor engines had already completed more than 1200 seconds (20 minutes) of cumulative hot-fire tests, an extremely aggressive and encouraging rate of progress for such a new engine.

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Although Raptor undoubtedly borrows heavily from much of the same expertise that designed Merlin 1 and operated and improved it for years, that is roughly where the similarities between Raptor and M1D end. M1D, powered by refined kerosene (RP-1) and liquid oxygen, uses a combustion cycle (gas-generator) that is relatively simple and reliable at the cost of engine efficiency, although SpaceX propulsion expertise still managed to give M1D the highest thrust-to-weight ratio of any liquid rocket engine ever flown. Still, measured by ISP (instantaneous specific impulse), M1D’s inefficient kerolox gas-generator cycle ultimately means that the engine simply can’t compete with the performance of engines with more efficient propellants and combustion cycles.

While SpaceX’s Falcon 9 and Heavy rockets – powered by Merlin 1D and Merlin Vacuum – are more than adequate in and around Earth orbit, a far more efficient engine was needed for the company to enable the sort of interplanetary colonization Musk had in mind when he created SpaceX. Raptor was the answer. Ultimately settling on liquid methane and oxygen (methalox) as the propellant and a full-flow staged-combustion (FFSC) cycle, Raptor was designed to be extraordinarily reliable and efficient in order to safely power a spacecraft (BFS/Starship) meant to ferry dozens or hundreds of people to and from Mars.

An excellent NASASpaceflight article explores the engine’s journey from a blank sheet to integrated static-fire tests and offers a deeper explanation of the technical details.

Raptor enters a new era

For all the extensive and invaluable testing SpaceX has done with a series of prototype Raptor engines, the engines tested were subscale versions with around 30% the thrust of the c. 2016 Raptor and around 40-50% of the updated c. 2017 iteration, producing almost the same amount of thrust as Merlin 1D (914 kN to Raptor’s ~1000 kN). In September 2018, Musk described Raptor as an “approximately…200-ton (~2000 kN) thrust engine” that would eventually operate with a chamber pressure as high as 300 bar (an extraordinary ~4400 psi), requiring at least one of the FFSC engine’s two preburners (used to power separate turbopumps) to operate at a truly terrifying ~810 bar (nearly 12,000 psi).

Conveniently stood beside a Merlin 1D engine also ready for hot-fire acceptance testing, the Raptor engine spotted departing SpaceX’s Hawthorne, CA factory last week was reportedly immense in person, towering over an M1D engine. Raptor also featured a mass of spaghetti-like plumbing (complexity necessary for its advanced combustion cycle), with a significant fraction of the metallic pipes and tubes displaying mirror-like finishes. Most notable was an obvious secondary preburner/turbopump stack and the lack of any exhaust port, whereas M1D relies on a single turbopump and exhausts the gases used to power it. Raptor’s full-flow staged-combustion cycle uses separate oxygen and methane preburners to power separate turbopumps, significantly improving mass flow rate and smoothing out combustion mixing.

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Unlike all previous hot-fired Raptors, those shipping now to McGregor, Texas are expected to be the first completed engines with a finalized design, arrived at only after a period of extensive testing and iterative improvement. They also appear to be full-scale, meaning that the test bays dedicated to Raptor will likely need to be upgraded (if they haven’t been already) to support a two- or threefold increase in maximum thrust.

SpaceX’s Starship hopper will need three finalized engines, meaning that the Raptor now in McGregor, Texas may not have been the first to arrive. Nevertheless, the shipment of full-scale hardware is always an extremely encouraging milestone for any advanced technology development program, while also foreshadowing the first imminent static-fires of the “radcally redesigned” rocket engine. With hardware now at the test site before January is out, a February test debut – one month behind a January debut teased by Elon Musk last December – is not out of the question.

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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’s new $29B Tesla stock award gets strange synopsis from governance firm

Did CGI not realize that Tesla Shareholders supported Musk being paid not once, but twice?

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5 hours ago

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August 12, 2025

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elon musk speaking
Credit: TED

Elon Musk was recently awarded around $29 billion in Tesla stock as the company’s Board of Directors is attempting to get its CEO paid after his original pay package was denied twice by the Delaware Chancery Court.

But a new and strange synopsis from the Corporate Governance Institute (CGI) says the award is potentially a strength move to “endorse the will of a powerful CEO.” The problem is, in the same sentence, the firm said the new award brings up a “question of whether the board exists to steward a company in the interests of all stakeholders.”

The problem with their new analysis of Musk’s pay package is that shareholders voted twice on Musk’s original pay package of $56 billion. They voted to give Musk that sum on two separate occasions.

Musk’s original $56 billion pay package was approved by shareholders twice; once in 2018 and once again last year. Last year’s vote was in response to Delaware Chancery Court Kathaleen McCormick’s decision to revoke the “unfathomable sum” from Musk.

Shareholders still showed support for Musk getting paid. Tesla said in its new award to the CEO that this is a way to give him compensation for the first time in seven years.

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CGI said in its note (via TipRanks):

“When a board builds its strategy around a single individual, it creates a concentration risk, not just operationally, but culturally and ethically. If that individual becomes a source of volatility, the company becomes fragile by design.”

What’s strange with this type of narrative is the fact that Tesla’s valuation has skyrocketed with Musk at the helm. Go back to 2020, and the stock is up over 200 percent. Since Musk’s $56 billion pay package was introduced in 2018, shares are up well over 1,000 percent.

Tesla engineer explains why Elon Musk deserves new pay package

Musk’s 2018 pay package was also not awarded to him without performance-based incentives. He was required to reach certain growth goals, all of which were accomplished through the launch of new vehicles and the advancements of its driver-assistance suites, like Autopilot and Full Self-Driving.

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It is tough to agree with CGI’s perception of Musk’s new pay plan, especially as it is much less than what shareholders voted on twice. Musk deserves to be paid for his contributions to Tesla.

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Tesla Robotaxi is headed to New York City, but one thing is in its way

Tesla is working to hire Vehicle Operators in New York City, but the company still needs some regulatory hurdles to go through.

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6 hours ago

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August 12, 2025

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tesla store in New York City
Credit: Tesla

Tesla Robotaxi will be headed to New York City, but there is one huge thing that stands in its way: approval to test autonomous vehicles.

Tesla is expanding its Robotaxi platform across the United States as it currently operates in Austin, Texas, and the Bay Area of California.

The company has also been seeking approvals in several other states, including Nevada, Arizona, and Florida.

However, the company is also working to expand to major metropolitan areas across the U.S. that it has not explicitly mentioned, as it attempts to reach CEO Elon Musk’s goal of giving half of the country’s population access to the platform by the end of the year:

It appears New York City is next on the list, according to a job posting on Tesla’s Careers website.

The company says it is hiring a Vehicle Operator for Autopilot in Flushing, New York, a section of the borough of Queens. Queens is connected to Brooklyn and Long Island, so it seems more ideal than launching in Manhattan or the Bronx, where traffic is heavy and charging is not as readily available.

Tesla’s job posting states:

“We are looking for a highly motivated self-starter to join our vehicle data collection team. As a Prototype Vehicle Operator, you will be responsible for driving an engineering vehicle for extended periods, conducting dynamic audio and camera data collection for testing and training purposes. Access to the data collected is limited to the applicable development team. This role requires a high level of flexibility, strong attention to detail, excellent driving skills, and the ability to thrive in a fast-paced, dynamic environment.”

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It also lists the hours of operation as Tuesday through Saturday or Sunday through Thursday, with its three shifts listed as:

  • Day Shift: 6:00 AM – 2:30 PM or 8:00 AM – 4:30 PM
  • Afternoon Shift: 2:00 PM – 10:30 PM or 4:00 PM – 12:30 AM
  • Night Shift: 10:00 PM-6:30 AM or 12:00 AM-8:30 AM

We wouldn’t count on New York City being the next place Tesla launches Robotaxi. According to a report from CNBC, a spokesperson for the NYC Department of Transportation confirmed Tesla has not yet applied for permits that are needed to operate its ride-hailing service.

For what it’s worth, it could just be the first step in Tesla’s plans. It also has Vehicle Operator job postings in other regions. Houston, Texas, as well as Tampa, Miami, and Clermont, Florida, are all listed on Tesla’s Career postings.

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Tesla’s Elon Musk gives nod to Ford while acknowledging his influence on EVs

“Ford basically invented mass manufacturing of large, complex products. Everyone else copied.”

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7 hours ago

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August 12, 2025

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elon-musk-jim-farley-tesla-ford
Credit: Tesla, Ford

Tesla CEO Elon Musk gave a tremendous nod to Ford while also acknowledging his own influence on EVs and the automotive industry in general.

Yesterday, Ford announced its new manufacturing process for EVs, which was essentially a rebirth of its own production lines and plans for more affordable models to offer consumers.

It was important to recognize that Ford truly launched automotive manufacturing with its production of the Model T 122 years ago.

That’s exactly what Musk did in a response to Ford CEO Jim Farley:

In the over 100 years since Ford started producing vehicles, the company has had one significant fact go under the radar: it truly created a great process for building large, complex vehicles. It is something that many companies eventually adopted as the car industry took off.

Tesla is in a similar situation. It has used things like the Giga Press from the Italian company IDRA to create a better, more efficient, streamlined process for building cars.

It was able to use casting to eliminate a vast majority of parts from the Model Y, which not only helped increase manufacturing efficiency but also improved safety and structural rigidity. It truly revolutionized manufacturing for the company, and Ford said that it would adopt a similar mindset with its new EVs.

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Yesterday, Doug Field, the Chief EV, Digital and Design Officer for Ford, and a former Sr. VP of Engineering for Tesla, said the company was taking the mentality that “the best part is no part.”

Musk acknowledged how far it has come and how it is influencing other car companies to do the same in terms of its production strategy:

Ford is using an “Assembly Tree,” which is essentially very similar to Tesla’s “unboxed production process.” In addition to the use of Gigacasting, which Ford is calling “Unicasting,” as well as the use of structural batteries, it is almost as if Tesla is having its own “Model T moment.”

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Ford has been quick to adopt an EV mentality as it plans to transition its business over the next decades. It is working to prepare for the future of the atuomotive industry, and although it has adjusted its strategy, it can’t be denied that Ford is one of the legacy automakers taking this new chapter in cars seriously.

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