News
SpaceX sends “radically redesigned” Starship engine to Texas for hot-fire tests
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.
Engines currently on Starship hopper are a blend of Raptor development & operational parts. First hopper engine to be fired is almost finished assembly in California. Probably fires next month.
— Elon Musk (@elonmusk) January 5, 2019
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.
Mach diamonds pic.twitter.com/TCX7ZGFnN0
— Elon Musk (@elonmusk) September 26, 2016
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.
SpaceX has completed over 1,200 seconds of firing across 42 main Raptor engine tests. pic.twitter.com/EhxbPjd8Cj
— SpaceX (@SpaceX) September 29, 2017
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.
- The only official render of Raptor, published by SpaceX in September 2016. The Raptor departing Hawthorne in Jan ’19 looked reasonably similar. (SpaceX)
- SpaceX technicians wrench on Merlin 1D and Merlin Vacuum engines. Raptor was apparently dramatically larger in person. (SpaceX)
- Starhopper’s Raptors feature a very distinct seam and second curve, indicative of a dual-bell nozzle. (NASASpaceflight /u/bocachicagal)
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.
- SpaceX’s current Texas facilities feature a test stand for Raptor, the engine intended to power BFR and BFS to Mars. (SpaceX)
- SpaceX’s subscale Raptor engine has completed more than 1200 seconds of testing in less than two years. (SpaceX)
- A gif of Raptor throttling over the course of a 90+ second static-fire test in McGregor, Texas. (SpaceX)
- A September 2018 render of Starship (then BFS) shows one of the vehicle’s two hinged wings/fins/legs. (SpaceX)
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.
Yes. Radically redesigned Raptor ready to fire next month.
— Elon Musk (@elonmusk) December 22, 2018
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.
News
NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded
NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.
NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.
SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.
We’re excited for Falcon 9 and Dragon to launch @NASA’s Crew-15, 16, and 17 missions to the @Space_Station from Florida https://t.co/Qm16vVK9F3 pic.twitter.com/drg3s7GtuM
— SpaceX (@SpaceX) September 18, 2026
The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.
Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.
Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.
Investor's Corner
New drone video shows Tesla’s Optimus Factory reaching a turning point
New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.
Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.
The Giga Texas Optimus Factory latest update … construction keeps moving fast!
Steel assembly is now only about 5 column grids from the north perimeter beam. Concrete is going in on the three upper floors, rebar is still being laid for more pours, and footing / grade-beam work… pic.twitter.com/qvFPvwnYzW
— Joe Tegtmeyer 🚀 🤠🛸😎 (@JoeTegtmeyer) September 17, 2026
Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.
Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.
Tesla Giga Texas to feature massive Optimus V4 production line
The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.
Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.
Investor's Corner
Tesla and SpaceX take “Terafab” Trademark fight to Federal Court
Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.
Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.
The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.
What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.
Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry
By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.
TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.
Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.
The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.






