News
SpaceX repairing upgraded Starship prototype after first test
SpaceX workers have been spotted repairing the company’s newest Starship prototype in the days after the rocket’s first partial test.
Starship S24 was transported to SpaceX’s Starbase, Texas orbital launch site (OLS) on May 26th after about two and a half months of assembly, marking the first time SpaceX transported a new Starship prototype to a test stand since August 2021. Less than 24 hours later, after attaching Ship 24 to a new test bay located beside the actual ‘orbital launch mount,’ the Starship prototype came to life and began its first proof test.
Unfortunately, while it’s impossible to judge with certainty without official confirmation, Ship 24 either failed to complete that test or did not make it through unscathed.
Known as an ambient or pneumatic proof test, the main goal is to pressurize a Starship or Super Heavy prototype with nonflammable, ambient-temperature nitrogen gas to ensure that the rocket and all its plumbing are structurally sound and working as expected. A successful test would likely require a prototype to reach and sustain flight pressures – up to 8.5 bar (~125 psi) as of 2020 – without exhibiting any significant leaks or problems.
For a while, Ship 24’s first ambient proof test went about as expected, with lots of small vents from its main liquid oxygen (LOx) and methane (LCH4) tanks. No activity was visible at the ship’s nose, where vents and plumbing attach to a pair of small landing (header) propellant tanks. Ship 24 is the first Starship with an upgraded version of those tanks after SpaceX decided to remove the methane header tank from the main methane tank and relocate it directly under the oxygen header tank, which takes up the tip of Starship’s nose.
After an hour or two of testing, a muffled bursting noise different from previous vents was heard, followed by a quieter ‘whoosh’ more akin to a long vent. At the same time as the loud noise was heard, a good dozen or so of S24’s thousands of heat shield tiles were knocked off the section of the hull between the Starship’s main tanks and nose cone. SpaceX depressurized Ship 24 soon after and within a few hours, workers could be seen extracting a pipe from the ship that appeared to have been bent almost in half.
Three days later, workers were spotted guiding apparent replacement pipes into Ship 24. Altogether, it appears that some small section of Ship 24’s internal piping failed catastrophically after it was pressurized during the vehicle’s first pneumatic proof test, knocking tiles loose and possibly damaging other adjacent plumbing. Given the location of that piping inside Ship 24’s nose section, there’s a nonzero chance that the failure occurred when SpaceX attempted to pressurize the Starship’s new header tanks, which would have started by pressurizing the propellant and gas lines leading to them. That would explain the first muffled burst, the subsequent venting sound that slowly faded to nothing, and the loss of heat shield tiles.
It would also explain why SpaceX decided to leave Starship in place and conduct repairs at the pad. Super Heavy Booster 7, which suffered a dramatic plumbing failure during an early proof test, was moved back to one of Starbase’s covered assembly bays for repairs. Had Ship 24’s incident been severe, it would have likely left the pad as well. The fact that Ship 24 did not move indicates that the failure was fairly minor and contained, only impacting some easily-replaceable plumbing.
Additionally, SpaceX appears to have moved Raptor heat shield components and a missing cover for one of Ship 24’s four flaps to the pad since the incident. On top of the team that has been working all weekend to repair the Starship, other sets of workers have set about closing out Ship 24’s ‘raceway’, which protects hundreds of feet of smaller plumbing and cables and a flight termination system that runs from the top to the bottom of the ship’s tanks; and some have begun preparing to fill gaps in Ship 24’s heat shield. Most of that work can be classified as ‘finishing touches’ and none of it would be prioritized if Ship 24 was not in decent shape.
Still, even minor damage is a setback. Ship 24’s next opportunity for redemption is a 10am to 10pm CDT window on Wednesday, June 1st, with backup windows available on Thursday and Friday.
Tesla is set to inaugurate its dedicated Semi factory in Sparks, Nevada, this evening, but drone footage has already started to show who is expected on the handover stage.
Zanegler, a drone operator who regularly documents Tesla Semi operations in Nevada, filmed a row of new-generation Semi units parked outside of the plant with customer branding applied. The liveries visible in the video include companies like PepsiCo, U.S. Foods, Einride, DHL, WattEV, and others that have committed to utilizing Tesla’s Class 8 electric truck in their fleets.
Tesla Semi Pre-Reveal Revealed!
Excited to share this segment of the drone flight one day prior to the Tesla Semi Reveal event.
They have added branding to several Tesla new generation semis.
Including:
Pepsico
US Foods
Einride
LTS
Nevoya
OK Produce
ABF Freight
DHL
WattEV… pic.twitter.com/KoFOg2FouR— Zanegler (@HinrichsZane) September 24, 2026
Several of those company names already sit within Tesla’s public ordering book, including PepsiCo, which has been the program’s primary anchor customer since the first Semi deliveries in December 2022. PepsiCo now runs dozens of Tesla Semi units in daily service, with drivers completing regional routes.
Einride placed a 500-unit order in August, which was, at the time, the largest single Semi commitment. First deployments of their Semi units are planned for this month and will eventually span across California, Texas, New Jersey, Illinois, and Georgia. Meanwhile, IMC Logistics announced a 50-truck California order this week.
Tesla Semi lands the biggest electric truck deal in U.S. history
Other names, like LTS, OK Produce, and HMD, have not been widely confirmed as firm buyers, but their presence on the lot is perhaps the clearest signal that Tesla intends to expand on that list this evening at the event.
Tesla first unveiled the Semi back in 2017 with a 2019 production target.
Limited pilot builds reached PepsiCo in late 2022, and high-volume production began at the new 1.7-million-square-foot plant that sits logically positioned next to Tesla’s Gigafactory Nevada. Tesla Semi program director Dan Priestley has said that Tesla expects to build “many thousands” of Semi units this year, but as with every Tesla release, there have been set expectations of an S-curve ramp.
Outside estimates still put 2026 deliveries in the 5,000-to-15,000 range, but it will ultimately depend on Tesla’s readiness to put those units out, as well as how smoothly production is moving internally.
Tesla’s Semi Rollout event is set to start tonight at the Sparks factory, and it will be livestreamed on X starting at 6 p.m. PDT / 9 p.m. ET.
The Tesla App is now giving owners a better indication of what to expect when visiting a Supercharger site, as it is now sharing Site Maps in the app itself, making the feature no longer exclusively available in the car.
Tesla owners can now preview a Supercharger’s layout and live stall status from their phone thanks to the App’s new software version, v4.61.0. Zooming into a supported Supercharger on the charging map now switches the familiar street view into a site-specific map that shows stall positions, occupied bays, out-of-service posts, and a live count of open Superchargers.
It will even show you which specific Tesla model is charging at each occupied stall.
You can now see Live Site Maps in the latest Tesla app (4.61.0.) pic.twitter.com/JIL8QzR8hu
— Zack (@BLKMDL3) September 18, 2026
This is the same view drivers first saw inside the car with the 2025 Holiday Update, which started as a pilot for Tesla in California and Texas. Those early maps showed layout, nearby amenities, and the status of each operational stall. The feature has spread to most Superchargers in the U.S., but now Tesla wants the feature available through the Smartphone App, which is now rolling out to owners.
The in-vehicle screen maps remain a richer 3D canvas and originally required AMD Ryzen infotainment hardware, which left many Intel-based Model 3 and Model Y owners without the view. The app version removes that hardware barrier, so any owner can now get a preview of their upcoming Supercharger stop on their phone.
Anyone with the updated version of the app can open a Site Map on their phone. The feature has provided some additional peace of mind to anxious travelers and those who might be looking for a place that is less congested for faster charging speeds. It is a meaningful addition to many owners, especially for trips to unfamiliar locations.
You can now pick a Supercharger location that might be more aligned with what you are looking for or need: you can pick a site based on what stalls are open, where ADA stalls sit, how you will pull in, and more, instead of circling a crowded lot after arriving. Owners of older cars now have access to the feature without having to purchase a new vehicle altogether.
Site Mpas will not reserve a stall, nor will it change how Fast Charging works. Tesla does something simpler and more useful by giving owners a dedicated preview of the Supercharger they’re about to charge, turning an unknown parking lot into a place that may seem more familiar thanks to the preview.
Interested in ordering a Tesla? Use my referral code for three free months of Full Self-Driving (Supervised) here.
Investor's Corner
Tesla Optimus Gen 3 shows off a cleaner, factory-ready design in new app discovery
Renders hidden inside Tesla’s Android app show Optimus Gen 3’s design before any official reveal.
![Tesla Optimus Gen 3 [Credit: Tesla]](https://www.teslarati.com/wp-content/uploads/2026/03/tesla-optimus-gen3-diner.jpg)
Tesla may have accidentally given a first look at its newest Optimus Gen 3 humanoid robot when photos were found in the Tesla smartphone app.
Design files tucked inside a recent Android version of the Tesla app appear to show the third generation humanoid robot next to the older Gen 2.5 prototype. The assets were extracted from the app package by Tesla community member @wholemars, who posted the renders on X late Tuesday night before deleting them. The Tesla Newswire reshared the side by side comparison on Wednesday, and the images have circulated widely since.
Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X
The files are labeled “gen3” and were built as models for Tesla app’s own interface, as validated directly by Grok to be official.
The comparison shows a robot that looks built for a factory line rather than a lab bench. Gen 2.5’s exposed mechanical linkages and gold plating on the knees and shins are gone. In their place, Gen 3 uses matte black fairings on the lower legs, paired with a more contoured champagne gold body. Flexible covers now seal the joint where the torso meets the upper thighs, keeping bearings and moving parts sealed from debris and unnecessary contact.
The body panels fit more tightly, and the hands, which Tesla has said carry 22 degrees of freedom, look far more refined than those on earlier units.
This most recent leak fills a gap Tesla has left open for most of the year. Elon Musk said on March 31 that Optimus 3 was walking around but needed “some finishing touches” before it could be shown, a delay Teslarati covered when Tesla missed its first quarter reveal target. Musk later said Tesla would hold the design back until closer to production, partly to keep competitors from copying it. No reveal date has been announced.
The app itself has been preparing for Optimus for months. In July, code in the Tesla app pointed to a dedicated robot phone key, a consent screen for collecting video and spatial data while Optimus works inside a home, and an alert system for low battery and mechanical faults. Finished 3D models of Gen 3 suggest the interface owners will eventually use is moving past placeholder code toward something Tesla intends to ship.
Manufacturing is moving in parallel. Tesla tore out the original Model S and Model X lines at Fremont this summer to make room for Optimus production, with a planned capacity of one million robots a year. At Giga Texas, the steel frame of a dedicated Optimus factory is nearing completion ahead of a targeted 2027 start, with Musk pointing to an eventual output of 10 million units annually.
Tesla leaks Semi customers ahead of handover event
Tesla App now shows you what your Supercharger will look like upon arrival
![Tesla Optimus Gen 3 [Credit: Tesla]](https://www.teslarati.com/wp-content/uploads/2026/03/tesla-optimus-gen3-diner-80x80.jpg)
