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SpaceX’s Raptor engine nears flight-readiness for BFR spaceship hop tests

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In a presentation that revealed plans for a private mission to the Moon in as early as 2023, SpaceX CEO Elon Musk dedicated a couple minutes to BFR’s booster and spaceship rocket engine of choice, Raptor. Musk had nothing but praise for SpaceX’s propulsion engineers and technicians, stating that he was “really excited” about the propulsion system’s advanced design.

Judging from a total of 1200 seconds of hot-fires completed just under a year ago, it’s safe to assume that Raptor has soared beyond that measure. Most recently, photos captured earlier this summer showed that a new prototype was installed on SpaceX’s horizontal Raptor test stand in McGregor, Texas, looking nearly identical to the deep black Raptor nozzle shown in Monday’s presentation. Previous Raptor prototypes seen during testing or at the test stand appeared to have a nozzle closer to SpaceX’s silver Merlin 1Ds, whereas this newest iteration’s nozzle doesn’t seem to reflect the powerful spotlights surrounding it.

Perhaps not a coincidence, SpaceX’s propulsion engineering lead Tom Mueller stated in May 2018 that flight-ready Raptors were already “in work”, with the implication being that the finalized Raptor design had been completed and that manufacturing work was beginning in earnest. Barring an unexpected shift in testing strategies, SpaceX will optimize and verify Raptor’s flight design over the course of several hundred seconds of static fire tests, eventually leading into the same practices used for Falcon 9.

 

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“This is a stupidly hard problem and SpaceX engineering has done a great job with this design.” In a May 2018 tweet, Musk added that “this engine is something special.” – Elon Musk, 09/17/18

Prior to being installed on any BFR prototypes, all Raptors will thus go through acceptance testing in Texas, potentially followed by a full-up static fire of the first completed BFR spaceships. Falcon 9 boosters – capable of roughly 7600 kN (1.7 million lbf) of thrust – are routinely tested in McGregor, while a full BFR spaceship with 2017-grade Raptors (1700 kN at sea level) would produce 12,000 kN (2.7 million lbf) of thrust with all Raptors firing. However, due to the sheer difficulty of transporting something 9 meters in diameter by road, it’s more likely that SpaceX will need to build up a dedicated static fire and hop test facility near the coast of Texas, at a spot called Boca Chica.

Getting to hop tests

As it turns out, massive propellant storage tanks (vacuum insulated) have already begun arriving at SpaceX’s Boca Chica facilities, currently dedicated to a duo of tracking and communications radars to be used for Crew Dragon communications. Over the course of the next 12 or so months, SpaceX is thus likely to expand and develop its Boca Chica facilities, culminating – if all goes well – sometime late next year with the first shipment of a prototype BFR spaceship from Port of Los Angeles, through the Panama Canal, to Port of Brownsville, Texas.

“I’m really excited about this engine design, I think the SpaceX propulsion team has done an amazing job – the SpaceX structures and aero team has done a phenomenal job in the design of this.”

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“Even others in the aerospace industry don’t know what question to ask – once we could frame the question [with precision], the answers [for Raptor and BFR R&D] flowed.” – Elon Musk, 09/17/18

A gif of Raptor throttling over the course of a 90+ second static-fire test in McGregor, Texas. (SpaceX)

SpaceX has already completed the first composite segment (both a section of the fuselage and of a propellant tank) of the first BFR spaceship prototype, and Musk further stated that BFR’s structural engineers and technicians would begin fabricating the spaceship prototype’s propellant tank domes and engine section “soon”. A vast amount of work remains to be completed before that prototype will begin to look anything like an actual spaceship, and the exact fidelity SpaceX is hoping to achieve with it is unclear.

If the company tries to get as close as possible to a finished product (within reason, of course) before beginning propulsive hop tests in Texas, a very late-2019 debut of that test campaign could be a practical goal. It’s not a perfect comparison, but Falcon 9 is perhaps the best prior example of SpaceX’s speed of development, moving from structural fabrication and testing (albeit with Falcon 5 in mind) in 2006 and 2007 to a full-up orbital launch of the first Falcon 9 in mid-2010, with milestones like the first static fire of a booster octaweb and nine Merlin 1C engines 6-12 months prior.


For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet check out our brand new LaunchPad and LandingZone newsletters!

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 set to launch astronauts and a classified Falcon Heavy mission on the same day

SpaceX plans three launches Thursday, including Crew-13 astronauts and Falcon Heavy’s first classified NRO mission.

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Crew Dragon sits atop Falcon 9 at sunrise on Cape Canaveral's pad 40, less than a day before four astronauts are set to launch to the ISS. (Credit: SpaceX)
Crew Dragon sits atop Falcon 9 at sunrise on Cape Canaveral's pad 40, less than a day before four astronauts are set to launch to the ISS. (Credit: SpaceX)

SpaceX is lining up one of the busiest single days in its history, and the company offered a preview on Wednesday morning with a simple post on X: “Sunrise at pad 40.” The video and photos show Falcon 9 standing at Space Launch Complex 40 at Cape Canaveral, roughly a day before it is scheduled to carry four astronauts to the International Space Station.

That launch is only the first of three SpaceX missions planned for Thursday, October 1, across both coasts.

Crew-13 is targeting liftoff at 11:10 a.m. ET, with a backup opportunity Friday at 10:47 a.m. ET. NASA astronaut Jessica Watkins will command the mission, with NASA’s Luke Delaney as pilot and Canadian Space Agency astronaut Joshua Kutryk and Roscosmos cosmonaut Sergey Teteryatnikov serving as mission specialists. According to NASA, Dragon is set to dock with the forward port of the station’s Harmony module around 8 p.m. ET, less than nine hours after launch. Watkins is the only member of the crew who has flown before, and Kutryk will become the first Canadian to reach orbit through NASA’s Commercial Crew Program.

The Falcon 9 booster is flying for the third time after supporting Crew-12 and a Starlink mission, and it will attempt a landing at Landing Zone 40 beside the pad. That site made its debut in February when the Crew-12 booster touched down there, as Teslarati reported at the time. Crew-13 will relieve the Crew-12 astronauts, who have been aboard the station since the middle of February.

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On the West Coast, another Falcon 9 is scheduled to lift off from Vandenberg Space Force Base in a window running from 2:18 to 3:16 p.m. ET, a flight NASASpaceflight lists as a Transporter rideshare mission.

The day is set to close at 11:53 p.m. ET, when Falcon Heavy launches from Launch Complex 39A with NROL-97, the first National Reconnaissance Office payload ever to fly on the rocket. SpaceX rolled the vehicle out to the pad Tuesday night. Its two side boosters, which previously flew GOES-U, ViaSat-3 F3 and NASA’s Roman Space Telescope, will return to Landing Zones 1 and 2, while a new center core will be expended in the Atlantic. The Roman launch took place on August 30, so NROL-97 will come barely a month later as Falcon Heavy’s third flight of 2026 and 14th overall.

NASA taps SpaceX to launch the telescope that could unlock new worlds

If all three Florida boosters land as planned, it would be the first time the Space Coast has seen landings at LZ-40, LZ-1 and LZ-2 on the same day, according to the Orlando Sentinel, which has warned residents in Brevard, Orange and Volusia counties that more than one sonic boom is possible.

The schedule arrives just three days after Starship reached orbit for the first time on Flight 14 from Starbase, Texas, deploying 26 Starlink V3 satellites. If Thursday’s missions stay on time, SpaceX will have flown Starship, Falcon 9 and Falcon Heavy from four different pads in about four days.

Crew-13 is also the start of a longer run for Dragon. NASA recently added Crew-15, Crew-16 and Crew-17 to SpaceX’s contract in a $946 million modification, keeping Dragon as the agency’s only operational ride to the station while Boeing’s Starliner remains grounded.

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Tesla Cybercab and Semi have more in common than you might think

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Credit: Tesla

Although the two vehicles are built for completely different use cases, Tesla utilized engineering expertise while developing both the Cybercab and Semi to build a thermal architecture that would fit both vehicles. Of course, with some slight revisions.

The development was noted by Lars Moravy and Dan Priestley last week at Tesla’s Semi Handover event in Sparks, Nevada, where the company showed off its dedicated production facility for the Class 8 truck.

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Tesla’s decision to develop one thermal architecture for both the Cybercab and Semi is one of the more revealing engineering choices in the company’s 2026 lineup:

“We designed it at the same time we designed the Cybercab and we said okay we’re going to take our most efficient vehicle and our biggest vehicle and we’re going to take one thermal system and make it work for both.”

Core parts, meaning the compressor, pumps, and heat exchangers, are shared, with only modest changes to cooling-loop sizing and a larger radiator on the truck. The result, they said, is a compressor and thermal stack already proven across millions of miles, delivering “reliability from day one.”

Priestley also highlighted a practical payoff of the indirect design:

“There’s no AC lines, there’s no refrigerant lines…It comes from the factory fully charged, sealed with refrigerant, and it just exchanges coolant. It doesn’t actually run refrigerant up to the front of the vehicle.”

This eliminates potentially leak-prone plumbing that would otherwise require hands-on service, reducing overall uptime and potentially cutting into business margins. The megamanifold runs cabin HVAC and every powertrain heating and cooling loop at once, recapturing waste heat from motors and the battery instead of dumping it the way a diesel engine does.

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The approach is just the latest chapter in a continuing story of stretching thermal solutions across wildly different vehicles. Model Y’s Octovalve evolved into the Super Manifold used on Cybertruck, and later Model S/X refreshes. Cybercab then introduced Supermanifold V3, which Tesla says is 80 percent automated to build and 38 percent more efficient than typical automotive thermal systems.

Tesla has done the same with the 4680 cells, both being utilized in the Cybertruck and Semi, and with heat-pump compressors that Priestley noted were already common across the passenger-car fleet.

Concurrent development of crucial vehicle elements buys scale and reliability that a truck-only thermal system could not match. High-volume passenger car parts are cheaper and more accessible, which can give fleets a sealed, low-maintenance loop of operation from their first day of operation.

For owners and operators, that translates into less energy spent on cabin heat in the colder months, fewer refrigerant-related repairs, and a thermal architecture already stress-tested at passenger-car volumes before the first high-volume Semi left the lines in Nevada.

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Elon Musk weather update tips Tesla Roadster speculation into Plaid Mode

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elon musk
Credit: Tesla

Tesla CEO Elon Musk certainly tipped off some details of the Tesla Roadster event with a broadening of information regarding the company’s decision to delay the unveiling for two weeks.

For years, people have speculated about what the Roadster will be capable of. While there have been plenty of things said about what it *could* do, we have not seen or been told by Tesla what it will actually be capable of.

However, over the past few days, Tesla’s weather updates have truly pushed the speculation into Plaid Mode, basically all but confirming the car will have some sort of aerial capability — whether that would be hovering or fully flying remains to be seen — but it definitely seems that it will be able to leave the ground intentionally.

“Because this event can only be held outdoors…”

Tesla posted on Monday that it would delay the Roadster event until October 15, and it indicated that it had to do this because the event “can only be held outdoors.”

With the potential SpaceX collaboration to develop cold-gas thrusters that will help the vehicle go airborne, doing this indoors is probably not a safe, or even plausible, possibility.

FAA Airspace Restriction

The FAA gave Tesla a Temporary Flight Restriction (TFR) for 10,000 feet above ground level, much higher than the typical 2,000-foot restrictions that are usually placed at SpaceX’s McGregor, Texas site.

Tesla Roadster event requires restricted airspace, and the FAA obliges

Some have said that this massive increase is due to Tesla’s need to restrict unauthorized drone use for spying on the event.

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Elon Admits High Winds

“Due to high winds, the new Roadster demo is postponed by 2 weeks,” Musk said in a post on X yesterday.

A reply reading, “What’s strong wind got to do with a car demo with four grounded wheels?” was directly below Musk’s post, satirically and sarcastically probing for more details.

All signs are pointing toward an aerial demonstration for the Roadster.

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